Study on the Process Characteristics Based on Joule Heat of Sliding-Pressure Additive Manufacturing

This study developed an experimental system based on Joule heat of sliding-pressure additive manufacturing (SP-JHAM), and Joule heat was used for the first time to accomplish high-quality single-layer printing. The roller wire substrate is short-circuited, and Joule heat is generated to melt the wire when the current passes through. Through the self-lapping experimental platform, single-factor experiments were designed to study the effects of power supply current, electrode pressure, contact length on the surface morphology and cross-section geometric characteristics of the single-pass printing layer. Through the Taguchi method, the effect of various factors was analyzed, the optimal process parameters were obtained, and the quality was detected. The results show that with the current increase, the aspect ratio and dilution rate of a printing layer increase within a given range of process parameters. In addition, with the increase in pressure and contact length, the aspect ratio and dilution ratio decrease. Pressure has the greatest effect on the aspect ratio and dilution ratio, followed by current and contact length. When a current of 260 A, a pressure of 0.60 N and a contact length of 1.3 mm are applied, a single track with a good appearance, whose surface roughness Ra is 3.896 μm, can be printed. Additionally, the wire and the substrate are completely metallurgically bonded with this condition. There are also no defects such as air holes and cracks. This study verified the feasibility of SP-JHAM as a new additive manufacturing strategy with high quality and low cost, and provided a reference for developing additive manufacturing technology based on Joule heat.