Study on arc behavior and droplet transfer mechanisms under complex paths

doi:10.1007/s40436-025-00559-8

Advances in Manufacturing ›› 2026, Vol. 14 ›› Issue (1): 172-188.doi: 10.1007/s40436-025-00559-8

Study on arc behavior and droplet transfer mechanisms under complex paths

Mao-Yuan Zhang¹, Yong-Hong Liu¹, Long-Fei Li¹, Chi Ma², Run-Sheng Li¹, Xin-Lei Wu¹, Yi-Bao Chen³, Li-Xin Wang¹, Ren-Peng Bian¹, Zhen-Ye Su¹, Fan-Bo Meng¹

1. College of Mechanical and Electronic Engineering, China University of Petroleum (East China), Qingdao, 266580, Shandong, People's Republic of China;
2. College of Mechanical and Electrical Engineering, Shaanxi University of Science and Technology, Xi'an, 710021, People's Republic of China;
3. School of Electromechanical and Automotive Engineering, Yantai University, Yantai, 264005, Shandong, People's Republic of China

收稿日期:2024-06-11 修回日期:2024-07-23 发布日期:2026-03-23
通讯作者: Yong-Hong Liu Email:E-mail:liuyhupc@163.com E-mail:liuyhupc@163.com
作者简介:Mao-Yuan Zhang is a Ph.D. candidate at China University of Petroleum (East China), focuses on the additive manufacturing, especially in wire arc additive manufacturing.
Yong-Hong Liu is a professor and doctoral supervisor at China University of Petroleum (East China). His current research interests include non-traditional machining, computer aided manufacturing and intelligent manufacturing.
Long-Fei Li is a master degree candidate at China University of Petroleum (East China), focuses on the additive manufacturing.
Chi Ma is a lecturer at Shaanxi University of Science and Technology, focuses on additive manufacturing, especially wire arc additive manufacturing.
Run-Sheng Li is a lecturer and master supervisor at China University of Petroleum (East China), focuses on the additive manufacturing, especially in wire arc additive manufacturing.
Xin-Lei Wu is currently an assistant research fellow with China University of Petroleum (East China). His current research interests include intelligent manufacturing and nontraditional machining.
Yi-Bao Chen is a professor and master supervisor at Yantai University. His current research interests include systems engineering and CAD-computer aided design.
Li-Xin Wang is a Ph.D. candidate at China University of Petroleum (East China), focuses on the special machining.
Ren-Peng Bian is a Ph.D. candidate at China University of Petroleum (East China), focuses on the special machining.
Zhen-Ye Su is a master degree candidate at China University of Petroleum (East China), focuses on the additive manufacturing.
Fan-Bo Meng is a Ph.D. candidate at China University of Petroleum (East China), focuses on the special machining.
基金资助:
This work was supported by the Taishan Scholars Project Special Fund (Grant Nos. tsqn202211085, tsqn202306118), the Natural Science Foundation of Shandong Province (Grant Nos. ZR2022ME106, ZR202212010161), and the Qingdao Postdoctoral Innovation Project (Grant No. QDBSH20240101039).

Study on arc behavior and droplet transfer mechanisms under complex paths

Mao-Yuan Zhang¹, Yong-Hong Liu¹, Long-Fei Li¹, Chi Ma², Run-Sheng Li¹, Xin-Lei Wu¹, Yi-Bao Chen³, Li-Xin Wang¹, Ren-Peng Bian¹, Zhen-Ye Su¹, Fan-Bo Meng¹

1. College of Mechanical and Electronic Engineering, China University of Petroleum (East China), Qingdao, 266580, Shandong, People's Republic of China;
2. College of Mechanical and Electrical Engineering, Shaanxi University of Science and Technology, Xi'an, 710021, People's Republic of China;
3. School of Electromechanical and Automotive Engineering, Yantai University, Yantai, 264005, Shandong, People's Republic of China

Received:2024-06-11 Revised:2024-07-23 Published:2026-03-23
Contact: Yong-Hong Liu Email:E-mail:liuyhupc@163.com E-mail:liuyhupc@163.com
Supported by:
This work was supported by the Taishan Scholars Project Special Fund (Grant Nos. tsqn202211085, tsqn202306118), the Natural Science Foundation of Shandong Province (Grant Nos. ZR2022ME106, ZR202212010161), and the Qingdao Postdoctoral Innovation Project (Grant No. QDBSH20240101039).

摘要/Abstract

摘要： Wire arc additive manufacturing (WAAM) is an economical and efficient technology for manufacturing large metal parts with complex physical states that are difficult to observe in situ. However, in-depth systematic research on the fluid flow state and droplet transition behavior in WAAM under complex paths is lacking. Firstly, the free surface of the molten pool was tracked using the volume-of-fluid (VOF) method. Subsequently, by integrating matrix transformation methods, the dual ellipsoidal heat source was varied over time, and its dynamic effects on the molten pool were studied. Finally, the shapes and sizes of the deposited bead and weld pool were determined. The results showed that the droplets brought heat and kinetic energy to the molten pool and that the kinetic energy of the molten pool was more easily dissipated on complex paths than on straight paths. The impact of droplets on the molten pool, creating a negative pressure, is one of the reasons for the precipitation of gas and the eventual formation of a unique bubble distribution. The primary reason for the tilt of the molten pool in the moving direction was the influence of the liquid tension and arc pressure. The simulated profiles of the deposited bead and droplet transfer are validated using experimental cross-sectional and high-speed camera images. The consistency between the simulation results and the experimental outcomes was good, aiding the precise control of specific requirements in future production.

The full text can be downloaded at https://doi.org/10.1007/s40436-025-00559-8

关键词: Wire arc additive manufacturing (WAAM), Heat and mass transfer, Numerical simulation, Path strategy

Abstract: Wire arc additive manufacturing (WAAM) is an economical and efficient technology for manufacturing large metal parts with complex physical states that are difficult to observe in situ. However, in-depth systematic research on the fluid flow state and droplet transition behavior in WAAM under complex paths is lacking. Firstly, the free surface of the molten pool was tracked using the volume-of-fluid (VOF) method. Subsequently, by integrating matrix transformation methods, the dual ellipsoidal heat source was varied over time, and its dynamic effects on the molten pool were studied. Finally, the shapes and sizes of the deposited bead and weld pool were determined. The results showed that the droplets brought heat and kinetic energy to the molten pool and that the kinetic energy of the molten pool was more easily dissipated on complex paths than on straight paths. The impact of droplets on the molten pool, creating a negative pressure, is one of the reasons for the precipitation of gas and the eventual formation of a unique bubble distribution. The primary reason for the tilt of the molten pool in the moving direction was the influence of the liquid tension and arc pressure. The simulated profiles of the deposited bead and droplet transfer are validated using experimental cross-sectional and high-speed camera images. The consistency between the simulation results and the experimental outcomes was good, aiding the precise control of specific requirements in future production.

The full text can be downloaded at https://doi.org/10.1007/s40436-025-00559-8

Key words: Wire arc additive manufacturing (WAAM), Heat and mass transfer, Numerical simulation, Path strategy

Mao-Yuan Zhang, Yong-Hong Liu, Long-Fei Li, Chi Ma, Run-Sheng Li, Xin-Lei Wu, Yi-Bao Chen, Li-Xin Wang, Ren-Peng Bian, Zhen-Ye Su, Fan-Bo Meng. Study on arc behavior and droplet transfer mechanisms under complex paths[J]. Advances in Manufacturing, 2026, 14(1): 172-188.

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Study on arc behavior and droplet transfer mechanisms under complex paths

Study on arc behavior and droplet transfer mechanisms under complex paths

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