A Novel Methodology to Manufacture Complex Metallic Sudden Overhangs in Weld-Deposition Based Additive Manufacturing

2021 ◽  
Author(s):  
Jayaprakash Sharma Panchagnula ◽  
Suryakumar Simhambhatla
Keyword(s):  
Additive Manufacturing ◽  
Tool Path ◽  
Gas Metal Arc Welding ◽  
Deposition Process ◽  
Raw Material ◽  
Illustrative Case ◽  
Metal Arc Welding ◽  
Deposition Direction ◽  
Directed Energy ◽  
Material Utilization

Abstract Amongst various additive manufacturing (AM) techniques for realizing the complex metallic objects, weld deposition (arc) based directed energy AM technique is attaining the more focus over commercially available powder bed fusion techniques. This is due to the capability of high deposition rates, high power and material utilization, simpler setup and less initial investment of arc based AM. Nevertheless, realization of sudden overhanging features through arc based weld deposition techniques is still a challenging task due to the necessity of support structures. The present work describes a novel methodology for producing complex metallic objects with sudden overhangs without using supports. This is possible by re-orienting the workpiece and/or deposition head at every instance using higher order kinematics (5-axis setup) to make sure the overhanging feature is in-line to the deposition direction. The proposed technique identifies the sudden overhangs form a CAD model (.stl) and generates an orthogonal tool path for deposition of the same. To validate this technique, objects with sudden overhangs (illustrative case studies) have been taken up for deposition. An In-house MATLAB routine has developed and presented for performing the same. Although this technique is suitable for any deposition process, it has been demonstrated using gas metal arc welding (GMAW) based weld-deposition, where the raw material to be deposited is in the form of a welding wire.

scholarly journals Analysis of the Wall Geometry with Different Strategies for High Deposition Wire Arc Additive Manufacturing of Mild Steel

Metals ◽  
2020 ◽  
Vol 10 (7) ◽  
pp. 892 ◽  
Author(s):  
Eider Aldalur ◽  
Fernando Veiga ◽  
Alfredo Suárez ◽  
Jon Bilbao ◽  
Aitzol Lamikiz
Keyword(s):  
Additive Manufacturing ◽  
Gas Metal Arc Welding ◽  
Low Carbon Steel ◽  
Utilization Rate ◽  
High Deposition Rate ◽  
Low Carbon ◽  
Metal Arc Welding ◽  
Geometric Precision ◽  
Directed Energy ◽  
Wire Arc Additive Manufacturing

Additive manufacturing has gained relevance in recent decades as an alternative to the manufacture of metal parts. Among the additive technologies, those that are classified as Directed Energy Deposition (DED) are characterized by their high deposition rate, noticeably, Wire Arc Additive Manufacturing (WAAM). However, having the inability to produce parts with acceptable final surface quality and high geometric precision is to be considered an important disadvantage in this process. In this paper, different torch trajectory strategies (oscillatory motion and overlap) in the fabrication of low carbon steel walls will be compared using Gas Metal Arc Welding (GMAW)-based WAAM technology. The comparison is done with a study of the mechanical and microstructural characteristics of the produced walls and finally, addressing the productivity obtained utilizing each strategy. The oscillation strategy shows better results, regarding the utilization rate of deposited material and the flatness of the upper surface, this being advantageous for subsequent machining steps.

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 Wire Arc Additive Manufacturing (WAAM) of Aluminum Alloy AlMg5Mn with Energy-Reduced Gas Metal Arc Welding (GMAW)

Materials ◽  
2020 ◽  
Vol 13 (12) ◽  
pp. 2671 ◽  
Author(s):  
Maximilian Gierth ◽  
Philipp Henckell ◽  
Yarop Ali ◽  
Jonas Scholl ◽  
Jean Pierre Bergmann
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Arc Welding ◽  
Energy Input ◽  
Large Scale ◽  
Unit Length ◽  
Gas Metal Arc Welding ◽  
Cold Metal Transfer ◽  
Metal Arc Welding ◽  
Wire Arc Additive Manufacturing

Large-scale aluminum parts are used in aerospace and automotive industries, due to excellent strength, light weight, and the good corrosion resistance of the material. Additive manufacturing processes enable both cost and time savings in the context of component manufacturing. Thereby, wire arc additive manufacturing (WAAM) is particularly suitable for the production of large volume parts due to deposition rates in the range of kilograms per hour. Challenges during the manufacturing process of aluminum alloys, such as porosity or poor mechanical properties, can be overcome by using arc technologies with adaptable energy input. In this study, WAAM of AlMg5Mn alloy was systematically investigated by using the gas metal arc welding (GMAW) process. Herein, correlations between the energy input and the resulting temperature–time-regimes show the effect on resulting microstructure, weld seam irregularities and the mechanical properties of additively manufactured aluminum parts. Therefore, multilayer walls were built layer wise using the cold metal transfer (CMT) process including conventional CMT, CMT advanced and CMT pulse advanced arc modes. These processing strategies were analyzed by means of energy input, whereby the geometrical features of the layers could be controlled as well as the porosity to area portion to below 1% in the WAAM parts. Furthermore, the investigations show the that mechanical properties like tensile strength and material hardness can be adapted throughout the energy input per unit length significantly.

scholarly journals Development of a Multidirectional Wire Arc Additive Manufacturing (WAAM) Process with Pure Object Manipulation: Process Introduction and First Prototypes

2021 ◽  
Vol 5 (4) ◽  
pp. 134
Author(s):  
Khushal Parmar ◽  
Lukas Oster ◽  
Samuel Mann ◽  
Rahul Sharma ◽  
Uwe Reisgen ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Gas Metal Arc Welding ◽  
Operating Conditions ◽  
Metal Arc Welding ◽  
Welding Torch ◽  
Building Process ◽  
Single Bead ◽  
Software Interfaces ◽  
Substrate Plate ◽  
Wire Arc Additive Manufacturing

Wire Arc Additive Manufacturing (WAAM) with eccentric wire feed requires defined operating conditions due to the possibility of varying shapes of the deposited and solidified material depending on the welding torch orientation. In consequence, the produced component can contain significant errors because single bead geometrical errors are cumulatively added to the next layer during a building process. In order to minimise such inaccuracies caused by torch manipulation, this article illustrates the concept and testing of object-manipulated WAAM by incorporating robotic and welding technologies. As the first step towards this target, robotic hardware and software interfaces were developed to control the robot. Alongside, a fixture for holding the substrate plate was designed and fabricated. After establishing the robotic setup, in order to complete the whole WAAM process setup, a Gas Metal Arc Welding (GMAW) process was built and integrated into the system. Later, an experimental plan was prepared to perform single and multilayer welding experiments as well as for different trajectories. According to this plan, several welding experiments were performed to decide the parametric working range for the further WAAM experiments. In the end, the results of the first multilayer depositions over intricate trajectories are shown. Further performance and quality optimization strategies are also discussed at the end of this article.

Rapid Manufacturing and Remanufacturing System Based on Robotic GMAW

2010 ◽  
Vol 156-157 ◽  
pp. 1626-1629 ◽  
Author(s):  
Zi Qiang Yin ◽  
Guang Jun Zhang ◽  
Hui Hui Zhao ◽  
Lin Wu
Keyword(s):  
Tool Path ◽  
Gas Metal Arc Welding ◽  
Three Dimensional ◽  
Rapid Manufacturing ◽  
Layer By Layer ◽  
Three Dimensional Model ◽  
Metal Arc Welding ◽  
Robotic Gmaw ◽  
Damaged Zone ◽  
Three Dimensional Models

This paper describes a novel rapid manufacturing and remanufacturing system based on robotic gas metal arc welding. If worn parts are maintainable, this system play a repairer role; if worn parts are unfit to remain in service, this system play a manufacturer role. This system works in ‘modeling - slicing - stacking’ principle. First, Detecting and building three-dimensional models of damaged zone by structured light. Second, Slicing established three-dimensional model in layers with some thickness. Third, planning robotic tool path to get optimumwelding path and parameters. Finally, executing remanufacturing task with robotic GMAW stacking layer by layer. This system remanufactures parts in human - robot interactive way. Take a half cylinder shell as worn part, experiments are conducted. Results show the mean error of surface smoothness is less than 0.5mm.

Twin-wire welding based additive manufacturing (TWAM): manufacture of functionally gradient objects

2017 ◽  
Vol 23 (5) ◽  
pp. 858-868 ◽  
Author(s):  
Somashekara M. Adinarayanappa ◽  
Suryakumar Simhambhatla
Keyword(s):  
Additive Manufacturing ◽  
Gas Metal Arc Welding ◽  
Filler Wire ◽  
Content Type ◽  
Functionally Gradient ◽  
Metal Arc Welding ◽  
Study Methodology ◽  
The Individual ◽  
Hardness Gradient ◽  
Suitable Process

Purpose Twin-wire welding-based additive manufacturing (TWAM) is a unique process which uses gas metal arc welding (GMAW)-based twin-wire weld-deposition to create functionally gradient materials (FGMs). Presented study aims to focus on creating metallic objects with a hardness gradient using GMAW of twin-wire weld deposition setup. Design/methodology/approach By using dissimilar filler wires in twin-wire weld-deposition, it is possible to create metallic objects with varying hardness. This is made possible by individually controlling the proportion of each filler wire used. ER70S-6 and ER110S-G are the two filler wires used for the study; the former has lower hardness than the latter. In the current study, methodology and various experiments carried out to identify the suitable process parameters at a given location for a desired variation of hardness have been presented. A predictive model for obtaining the wire speed of the filler wires required for a desired value of hardness was also created. Subsequently, sample parts with gradient in various directions have been fabricated. Findings For dissimilar twin-wire weld-deposition used here, it is observed that the resultant hardness is in the volumetric proportion of the hardness of the individual filler wires. This aids the fabrication of FGMs using arc based weld-deposition with localized control of hardness, achieved through the control of the ratio of wire speeds of the individual filler wires. Four sample parts were fabricated to demonstrate the concept of realizing FGMs through TWAM. The fabricated parts showed good match with the desired hardness variation. Research limitations/implications This paper successfully presents the capability of TWAM for creating gradient metallic objects with varying hardness. Although developed using ER70S-6 and ER110S-G filler wire combination, the methodology can be extended for other filler wire combinations too for creating FGMs Originality/value GMAW-based twin-wire welding for additive manufacturing is a novel process which uses dissimilar filler wires for creating FGMs. This paper describes methodology of the same followed by illustration of parts created with bi-directional hardness gradient.

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