scholarly journals Investigation of microstructure and hardness of a rib geometry produced by metal forming and wire-arc additive manufacturing

2018 ◽  
Vol 190 ◽  
pp. 02005 ◽  
Author(s):  
Markus Hirtler ◽  
Angelika Jedynak ◽  
Benjamin Sydow ◽  
Alexander Sviridov ◽  
Markus Bambach
Keyword(s):  
Additive Manufacturing ◽  
Metal Forming ◽  
Batch Size ◽  
Unit Costs ◽  
Batch Sizes ◽  
Traditional Manufacturing ◽  
Manufacturing Technologies ◽  
Forming Tools ◽  
Wire Arc Additive Manufacturing ◽  
Am Processes

Within the scope of consumer-oriented production, individuality and cost-effectiveness are two essential aspects, which can barely be met by traditional manufacturing technologies. Conventional metal forming techniques are suitable for large batch sizes. If variants or individualized components have to be formed, the unit costs rise due to the inevitable tooling costs. For such applications, additive manufacturing (AM) processes, which do not require tooling, are more suitable. Due to the low production rates and limited build space of AM machines, the manufacturing costs are highly dependent on part size and batch size. Hence, a combination of both manufacturing technologies i.e. conventional metal forming and additive manufacturing seems expedient for a number of applications. The current study develops a process chain combining forming and additive manufacturing. First, a semi-finished product is formed with forming tools of reduced complexity and then finished by additive manufacturing. This research investigates the addition of features using AlSi12 created by Wire Arc Additive Manufacturing (WAAM) on formed EN-AW 6082 preforms. By forming, the strength of the material was increased, while this effect was partly reduced by the heat input of the WAAM process.

A Review on Process Monitoring and Control in Metal-Based Additive Manufacturing

2014 ◽  
Vol 136 (6) ◽  
Author(s):  
Gustavo Tapia ◽  
Alaa Elwany
Keyword(s):  
Additive Manufacturing ◽  
Process Monitoring ◽  
Monitoring And Control ◽  
Part Quality ◽  
Industrial Sectors ◽  
Process Monitoring And Control ◽  
Traditional Manufacturing ◽  
Manufacturing Technologies ◽  
And Control ◽  
Am Processes

There is consensus among both the research and industrial communities, and even the general public, that additive manufacturing (AM) processes capable of processing metallic materials are a set of game changing technologies that offer unique capabilities with tremendous application potential that cannot be matched by traditional manufacturing technologies. Unfortunately, with all what AM has to offer, the quality and repeatability of metal parts still hamper significantly their widespread as viable manufacturing processes. This is particularly true in industrial sectors with stringent requirements on part quality such as the aerospace and healthcare sectors. One approach to overcome this challenge that has recently been receiving increasing attention is process monitoring and real-time process control to enhance part quality and repeatability. This has been addressed by numerous research efforts in the past decade and continues to be identified as a high priority research goal. In this review paper, we fill an important gap in the literature represented by the absence of one single source that comprehensively describes what has been achieved and provides insight on what still needs to be achieved in the field of process monitoring and control for metal-based AM processes.

scholarly journals The Corrosion of Stainless Steel Made by Additive Manufacturing: A Review

Metals ◽  
2021 ◽  
Vol 11 (3) ◽  
pp. 516
Author(s):  
Gyeongbin Ko ◽  
Wooseok Kim ◽  
Kyungjung Kwon ◽  
Tae-Kyu Lee
Keyword(s):  
Stainless Steel ◽  
Additive Manufacturing ◽  
Relevant Literature ◽  
Corrosion Property ◽  
Corrosion Study ◽  
Direct Laser ◽  
Manufacturing Methods ◽  
Traditional Manufacturing ◽  
Wire Arc Additive Manufacturing ◽  
Am Processes

The advantages of additive manufacturing (AM) of metals over traditional manufacturing methods have triggered many relevant studies comparing the mechanical properties, corrosion behavior, and microstructure of metals produced by AM or traditional manufacturing methods. This review focuses exclusively on the corrosion property of AM-fabricated stainless steel by comprehensively analyzing the relevant literature. The principles of various AM processes, which have been adopted in the corrosion study of stainless steel, and the corrosion behaviors of stainless steel depending on the AM process, the stainless steel type, and the corrosion environment are summarized. In this comprehensive analysis of relevant literature, we extract dominant experimental factors and the most relevant properties affecting the corrosion of AM-fabricated stainless steel. In selective laser melting, the effects of the scan speed, laser power, energy density, and the post-treatment technologies are usually investigated. In direct laser deposition, the most relevant papers focused on the effect of heat treatments on passive films and the Cr content. There has been no specific trend in the corrosion study of stainless steel that is fabricated by other AM processes, such as wire arc additive manufacturing. Given the rising utilization of AM-produced metal parts, the corrosion issue will be more important in the future, and this review should provide a worthwhile basis for future works.

scholarly journals A STRUCTURED APPROACH TO REDUCE DESIGN ITERATIONS IN ADDITIVE MANUFACTURING

2021 ◽  
Vol 1 ◽  
pp. 231-240
Author(s):  
Laura Wirths ◽  
Matthias Bleckmann ◽  
Kristin Paetzold
Keyword(s):  
Additive Manufacturing ◽  
Spare Parts ◽  
Design Guidelines ◽  
Final Part ◽  
Layer By Layer ◽  
Powder Bed ◽  
Batch Sizes ◽  
Manufacturing Technologies ◽  
Structured Approach ◽  
Design Freedom

AbstractAdditive Manufacturing technologies are based on a layer-by-layer build-up. This offers the possibility to design complex geometries or to integrate functionalities in the part. Nevertheless, limitations given by the manufacturing process apply to the geometric design freedom. These limitations are often unknown due to a lack of knowledge of the cause-effect relationships of the process. Currently, this leads to many iterations until the final part fulfils its functionality. Particularly for small batch sizes, producing the part at the first attempt is very important. In this study, a structured approach to reduce the design iterations is presented. Therefore, the cause-effect relationships are systematically established and analysed in detail. Based on this knowledge, design guidelines can be derived. These guidelines consider process limitations and help to reduce the iterations for the final part production. In order to illustrate the approach, the spare parts production via laser powder bed fusion is used as an example.

scholarly journals MODEL-BASED DESIGN OF AM COMPONENTS TO ENABLE DECENTRALIZED DIGITAL MANUFACTURING SYSTEMS

2021 ◽  
Vol 1 ◽  
pp. 2127-2136
Author(s):  
Olivia Borgue ◽  
John Stavridis ◽  
Tomas Vannucci ◽  
Panagiotis Stavropoulos ◽  
Harry Bikas ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Systems ◽  
Production Systems ◽  
Data Generation ◽  
Production Networks ◽  
Model Based ◽  
Manufacturing Technologies ◽  
Am Processes ◽  
Final Consumer

AbstractAdditive manufacturing (AM) is a versatile technology that could add flexibility in manufacturing processes, whether implemented alone or along other technologies. This technology enables on-demand production and decentralized production networks, as production facilities can be located around the world to manufacture products closer to the final consumer (decentralized manufacturing). However, the wide adoption of additive manufacturing technologies is hindered by the lack of experience on its implementation, the lack of repeatability among different manufacturers and a lack of integrated production systems. The later, hinders the traceability and quality assurance of printed components and limits the understanding and data generation of the AM processes and parameters. In this article, a design strategy is proposed to integrate the different phases of the development process into a model-based design platform for decentralized manufacturing. This platform is aimed at facilitating data traceability and product repeatability among different AM machines. The strategy is illustrated with a case study where a car steering knuckle is manufactured in three different facilities in Sweden and Italy.

scholarly journals Influence of Deposition Patterns on Distortion of H13 Steel by Wire-Arc Additive Manufacturing

Metals ◽  
2021 ◽  
Vol 11 (3) ◽  
pp. 485
Author(s):  
Xufeng Li ◽  
Jian Lin ◽  
Zhidong Xia ◽  
Yongqiang Zhang ◽  
Hanguang Fu
Keyword(s):  
Additive Manufacturing ◽  
Temperature History ◽  
H13 Steel ◽  
Deposition Patterns ◽  
Field Distortion ◽  
Set Up ◽  
Manufacturing Technologies ◽  
Inherent Strain ◽  
Inherent Strain Method ◽  
Wire Arc Additive Manufacturing

Wire-arc additive manufacturing (WAAM) has been considered as one of the potential additive-manufacturing technologies to fabricate large components. However, its industrial application is still limited by the existence of stress and distortion. During the process of WAAM, the scanning pattern has an important influence on the temperature field, distortion and final quality of the part. Four kinds of deposition patterns, including sequence, symmetry, in–out and out–in, were designed to deposit H13 steel in this study. An in situ measurement system was set up to record the temperature history and the progress of accumulated distortion of the parts during deposition. An S value was proposed to evaluate the distortion of the substrate. It was shown that the distortion of the part deposited by sequence was significantly larger than those of other parts. The distortion deposited by the out–in pattern decreased by 68.6% compared with sequence. The inherent strain method and strain parameter were introduced to expose the mechanism of distortion reduction caused by pattern variation.

scholarly journals Wire Arc Additive Manufacturing: Review on Recent Findings and Challenges in Industrial Applications and Materials Characterization

Metals ◽  
2021 ◽  
Vol 11 (6) ◽  
pp. 939
Author(s):  
Mukti Chaturvedi ◽  
Elena Scutelnicu ◽  
Carmen Catalina Rusu ◽  
Luigi Renato Mistodie ◽  
Danut Mihailescu ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Structural Integrity ◽  
Industrial Applications ◽  
Raw Material ◽  
Continuous Increase ◽  
Control Optimization ◽  
Modern Manufacturing ◽  
Directed Energy ◽  
Manufacturing Technologies ◽  
Wire Arc Additive Manufacturing

Wire arc additive manufacturing (WAAM) is a fusion manufacturing process in which the heat energy of an electric arc is employed for melting the electrodes and depositing material layers for wall formation or for simultaneously cladding two materials in order to form a composite structure. This directed energy deposition-arc (DED-arc) method is advantageous and efficient as it produces large parts with structural integrity due to the high deposition rates, reduced wastage of raw material, and low consumption of energy in comparison with the conventional joining processes and other additive manufacturing technologies. These features have resulted in a constant and continuous increase in interest in this modern manufacturing technique which demands further studies to promote new industrial applications. The high demand for WAAM in aerospace, automobile, nuclear, moulds, and dies industries demonstrates compatibility and reflects comprehensiveness. This paper presents a comprehensive review on the evolution, development, and state of the art of WAAM for non-ferrous materials. Key research observations and inferences from the literature reports regarding the WAAM applications, methods employed, process parameter control, optimization and process limitations, as well as mechanical and metallurgical behavior of materials have been analyzed and synthetically discussed in this paper. Information concerning constraints and enhancements of the wire arc additive manufacturing processes to be considered in terms of wider industrial applicability is also presented in the last part of this paper.

scholarly journals Design Right Once for Additive Manufacturing

2018 ◽  
Vol 188 ◽  
pp. 03020
Author(s):  
Antonios Tsakiris ◽  
Christos Salpistis ◽  
Athanassios Mihailidis
Keyword(s):  
Additive Manufacturing ◽  
Weight Reduction ◽  
Variable Density ◽  
Free Form ◽  
Structure Generation ◽  
Innovative Design ◽  
Key Factor ◽  
Traditional Manufacturing ◽  
Manufacturing Technologies ◽  
Free Form Surfaces

Additive Manufacturing (AM) has been widely considered a key factor for innovative design. However, the utilization of AM has not been as high as expected, although the technology offers key innovative design capabilities, weight reduction, parts count and assembly consolidation as well as material saving. This low utilization is attributed to the lack of AM understanding, mature CAE/CAM software tools addressing AM specific issues such as design support structure generation and removal, residual stresses, surface quality. In most cases, Design for AM (DfAM) is a crucial requisite for a “Design Right Once” approach. Such an approach is shown in the current study using three parts as example: an arthropod’s leg, a gearshift drum and an electric motor mounting frame. The implementation of geometrical conformal lattice structures and lattices with variable density are discussed. A structured design approach is presented and design dilemmas are solved in terms of a DfAM approach. Primary design optimizations are evaluated. Weight reduction is considered throughout the design and free form surfaces are being used. “Freedom to Design” principle is also portrayed and assembly parts consolidation occurs as a natural process of DfAM in comparison with previous design practices. It is concluded that, even from the primary design phase the design engineer can reveal his creativity because of the absence of constraints set by the traditional manufacturing technologies.

scholarly journals Influence of Interpass Temperature on Wire Arc Additive Manufacturing (WAAM) of Aluminium Alloy Components

2019 ◽  
Vol 269 ◽  
pp. 05001 ◽  
Author(s):  
Karan Derekar ◽  
Jonathan Lawrence ◽  
Geoff Melton ◽  
Adrian Addison ◽  
Xiang Zhang ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Tensile Properties ◽  
Deposition Pattern ◽  
Formed Product ◽  
Traditional Manufacturing ◽  
Wire Arc Additive Manufacturing ◽  
Interpass Temperature ◽  
Temperature Sample ◽  
Better Than

Wire arc additive manufacturing (WAAM) technique has revealed the potential of replacing existing aerospace industry parts manufactured by traditional manufacturing routes. The reduced mechanical properties compared to wrought products, the porosity formation, and solidification cracking are the prime constraints that are restricting wide-spread applications of WAAM products using aluminium alloys. An interpass temperature is less studied in robotic WAAM and is the vital aspect affecting the properties of a formed product. This paper highlights the effects of change in interpass temperature on porosity content and mechanical properties of WAAM parts prepared using DC pulsed GMAW process, with 5356 aluminium consumable wire. The samples prepared with different interpass temperatures were studied for the distribution of pores with the help of computed tomography radiography (CT radiography) technique. A WAAM sample produced with higher interpass temperature revealed 10.41% less porosity than the sample prepared with lower interpass temperature. The pores with size less than 0.15mm3 were contributing over 95% of the overall porosity content. Additionally, on a volumetric scale, small pores (<0.15mm3) in the higher interpass temperature sample contributed 81.47% of overall volume of pores whereas only 67.92% volume was occupied in lower interpass temperature sample with same sized pores. The different solidification rates believed to have influence on the hydrogen evolution mechanism. Tensile properties of higher interpass temperature sample were comparatively better than lower interpass temperature sample. For the deposition pattern used in this study, horizontal specimens were superior to vertical specimens in tensile properties.

scholarly journals Analysis of the Machining Process of Titanium Ti6Al-4V Parts Manufactured by Wire Arc Additive Manufacturing (WAAM)

Materials ◽  
2020 ◽  
Vol 13 (3) ◽  
pp. 766 ◽  
Author(s):  
Fernando Veiga ◽  
Alain Gil Del Val ◽  
Alfredo Suárez ◽  
Unai Alonso
Keyword(s):  
Additive Manufacturing ◽  
Arc Welding ◽  
Machine Tools ◽  
Optimal Strategies ◽  
Machining Process ◽  
Manufacturing Processes ◽  
Plasma Arc Welding ◽  
Traditional Manufacturing ◽  
Wire Arc Additive Manufacturing

In the current days, the new range of machine tools allows the production of titanium alloy parts for the aeronautical sector through additive technologies. The quality of the materials produced is being studied extensively by the research community. This new manufacturing paradigm also opens important challenges such as the definition and analysis of the optimal strategies for finishing-oriented machining in this type of part. Researchers in both materials and manufacturing processes are making numerous advances in this field. This article discusses the analysis of the production and subsequent machining in the quality of TI6Al4V produced by Wire Arc Additive Manufacturing (WAAM), more specifically Plasma Arc Welding (PAW). The promising results observed make it a viable alternative to traditional manufacturing methods.

Machines and Tools for Sheet-Bulk Metal Forming

2011 ◽  
Vol 473 ◽  
pp. 91-98 ◽  
Author(s):  
Marion Merklein ◽  
A. Erman Tekkaya ◽  
Alexander Brosius ◽  
Simon Opel ◽  
Lukas Kwiatkowski ◽  
...  
Keyword(s):  
Metal Forming ◽  
Incremental Forming ◽  
Batch Size ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
New Process ◽  
Novel Approaches ◽  
The Individual ◽  
Forming Tools ◽  
Functional Components

The demand on closely-tolerated and complex functional components in the automotive sector, like e.g. synchronizer rings, leads to the development of a new process-class named “sheet-bulk metal forming”. Within this technology bulk metal forming operations are applied on sheet metals. In the following two novel approaches considering machines and tools for sheet-bulk metal forming are presented. The first approach aims on a technology based on rolling, which is suitable for mass production. The second one is an incremental forming solution for low batch production. Both machine concepts allow the application of different forming strategies to manufacture individual tailored semi-finished products in term of a pre-distribution of material. These products feature variable sheet thicknesses and mechanical properties, which can be adapted to their case of applica-tion. Depending on the individual batch size, the blanks can be finished to functional parts by sub-sequent forming processes like deep drawing and upsetting, extrusion or incremental forming. In this paper the case of an incremental tooth-forming is mainly considered. Forming sequences and resulting loads are modeled and calculated by finite elements simulations for all discussed processes to serve as a basis for the design and dimensioning of the machine components and forming tools.

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