A Radiation-Based Analytical Model for the Computation of Temperature in the Arc Column of Submerged Arc Additive Manufacturing Process

Submerged Arc Additive Manufacturing (SAAM) is an advanced Wire Arc-based Additive Manufacturing (WAAM) technique known for its uniform deposition structure, high deposition rate, and superior surface finish. However, it is difficult and expensive to experimentally investigate the arc column in SAAM due to its submerged nature under flux. This paper presents an effective alternative: developing a radiation-based analytical model to predict the complex temperature distribution within the SAAM arc column. It focuses on the radiation heat transfer phenomenon since the temperatures attained inside the arc column are beyond the melting temperature of the material involved, and the presence of granular flux and slag intensifies the effect of the same. The model incorporates key input process parameters like wire diameter, stick-out length, current, voltage, and travel speed alongside design parameters like bead width, penetration depth, and material reinforcement. The double ellipsoidal heat source model is the foundation for generating the temperature profile. The predicted temperature profile resembles the double ellipsoid in other arc welding-based additive manufacturing techniques. The model's predictions showed a deviation of approximately 14% from experimental results, validating its effectiveness. Extensive parametric studies were carried out using the developed model. It was observed that longer stick-out lengths dampened temperature variations, while higher currents confined the affected zone further. Increased travel speed reduces the heating and cooling rate, while voltage behaves the opposite way. This analytical approach offers a cost-effective alternative for optimizing process parameters to achieve desired dimensions and deposition quality in SAAM applications.