scholarly journals Advanced computational modelling of metallic wire-arc additive manufacturing

2021 ◽  
Author(s):  
Dejan Kovšca ◽  
Bojan Starman ◽  
Aljaž Ščetinec ◽  
Damjan Klobčar ◽  
Nikolaj Mole
Keyword(s):  
Additive Manufacturing ◽  
Complex Geometry ◽  
Computational Modelling ◽  
Single Layer ◽  
Robotic Manipulator ◽  
Data File ◽  
Layer By Layer ◽  
Printing Technology ◽  
Material Layer ◽  
Wire Arc Additive Manufacturing

Wire-arc welding-based additive manufacturing (WAAM) is a 3D printing technology for production of near-net-shape parts with complex geometry. This printing technology enables to build up a required shape layer by layer with a deposition of a consumable welding wire, where the welding arc is a source of heat. Welding is usually performed by CNC-controlled robotic manipulator, which provides a controlled location of material layer adding. Because the process itself involves thermo-mechanically complex phenomena, Finite Element-based virtual models are commonly employed to optimize the process parameters. This paper presents advanced computational modelling of the WAAM of a tube. A thermo-mechanical numerical model of the process is calibrated against experimental data, measured as temperature variation at the acquisition point. The virtual modelling starts with a preparation of the tube geometry in CAD software, where the geometry of the single-layer cross-section is assumed. The geometry is then exported to a G-code format data file and used to control robotic manipulator motion. On the other side, the code serves as an input to in-house developed code for automatic FEs activation in the simulation of the material layer-adding process. The time of activation of the finite elements (FEs) is directly related to the material deposition rate. The activation of the FEs is followed by a heat source, modeled with a double ellipsoidal power density distribution. The thermo-mechanical problem was solved as uncoupled to speed-up computation.

scholarly journals WAAM Application for EPC Company

2019 ◽  
Vol 269 ◽  
pp. 05002
Author(s):  
Priyantomo Agustinus Ananda
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Process ◽  
Complex Geometry ◽  
Welding Process ◽  
Feed Speed ◽  
Layer By Layer ◽  
Delivery Time ◽  
Project Schedule ◽  
Wide Range ◽  
Wire Arc Additive Manufacturing

WAAM ( Wire + Arc Additive Manufacturing) is a process of adding material layer by layer in order to build a near net shape components. It shows a further promising future for fabricating large expensive metal components with complex geometry. Engineering Procurement and Construction (EPC) company as one of the industrial section which related with engineering design and products, wide range of material type, and shop based or site based manufacturing process have been dealing with conventional manufacturing and procurement process in order to fulfill its requirement for custom parts and items for the project completion purpose. During the conventional process, there is a risk during the transportation of the products from the manufacturing shop to then site project, this risk is even greater when the delivery time take part as one of the essential part which affect the project schedule. Wire Arc Additive Manufacturing process offering an alternative process to shorten the delivery time and process for a selected material and engineered items, with the consideration of essential variables which can affect the final products of WAAM process, such as : heat input, wire feed speed, travel speed, shielding gas, welding process and robotic system applied. In this paper, the possibilities of WAAM application in EPC company will be assessed, an in depth literature review of the various process which possible to applied, include the loss and benefit compared with conventional method will be presented. The main objective is to identify the current challenge and the prospect of WAAM application in EPC company.

scholarly journals Wire and Arc Additive Manufacturing of Aluminum Components

Metals ◽  
2019 ◽  
Vol 9 (5) ◽  
pp. 608 ◽  
Author(s):  
Markus Köhler ◽  
Sierk Fiebig ◽  
Jonas Hensel ◽  
Klaus Dilger
Keyword(s):  
Additive Manufacturing ◽  
Process Development ◽  
Complex Geometry ◽  
Welding Process ◽  
Surface Finishing ◽  
Process Conditions ◽  
Efficient Production ◽  
Layer By Layer ◽  
Cold Metal Transfer ◽  
Wire Arc Additive Manufacturing

An increasing demand for flexibility and product integration, combined with reduced product development cycles, leads to continuous development of new manufacturing technologies such as additive manufacturing. Wire and arc additive manufacturing (WAAM) provides promising technology for the near net-shape production of large structures with complex geometry, using cost efficient production resources such as arc welding technology and wire materials. Compared to powder-based additive manufacturing processes, WAAM offers high deposition rates as well as enhanced material utilization. Because of the layer-by-layer built up approach, process conditions such as energy input, arc characteristics, and material composition result in a different processability during the additive manufacturing process. This experimental study aims to describe the effects of the welding process on buildup accuracy and material properties during wire arc additive manufacturing of aluminum structures. Following a process development using pulse cold metal transfer (CMT-P), linear wall samples were manufactured with variations of the filler metal. The samples were analyzed in terms of surface finishing, hardness, and residual stress. Furthermore, mechanical properties were determined in different building directions.

Control of humping phenomenon and analyzing mechanical properties of Al–Si wire-arc additive manufacturing fabricated samples using cold metal transfer process

2021 ◽  
pp. 095440622199840
Author(s):  
Yashwant Koli ◽  
N Yuvaraj ◽  
Aravindan Sivanandam ◽  
Vipin
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Heat Input ◽  
Large Scale ◽  
High Deposition Rate ◽  
Bead Geometry ◽  
Layer By Layer ◽  
Cold Metal Transfer ◽  
Geometrical Shapes ◽  
Wire Arc Additive Manufacturing

Nowadays, rapid prototyping is an emerging trend that is followed by industries and auto sector on a large scale which produces intricate geometrical shapes for industrial applications. The wire arc additive manufacturing (WAAM) technique produces large scale industrial products which having intricate geometrical shapes, which is fabricated by layer by layer metal deposition. In this paper, the CMT technique is used to fabricate single-walled WAAM samples. CMT has a high deposition rate, lower thermal heat input and high cladding efficiency characteristics. Humping is a common defect encountered in the WAAM method which not only deteriorates the bead geometry/weld aesthetics but also limits the positional capability in the process. Humping defect also plays a vital role in the reduction of hardness and tensile strength of the fabricated WAAM sample. The humping defect can be controlled by using low heat input parameters which ultimately improves the mechanical properties of WAAM samples. Two types of path planning directions namely uni-directional and bi-directional are adopted in this paper. Results show that the optimum WAAM sample can be achieved by adopting a bi-directional strategy and operating with lower heat input process parameters. This avoids both material wastage and humping defect of the fabricated samples.

scholarly journals ADDITIVE MANUFACTURING - APPLICATION OPPORTUNITIES FOR THE AVIATION INDUSTRY

2015 ◽  
Vol 6 (2) ◽  
pp. 63-86
Author(s):  
Dipesh Dhital ◽  
Yvonne Ziegler
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Computer Aided Design ◽  
Free Form ◽  
Aviation Industry ◽  
Layer By Layer ◽  
Printing Technology ◽  
3D Printing Technology ◽  
Subtractive Manufacturing ◽  
Aided Design

Additive Manufacturing also known as 3D Printing is a process whereby a real object of virtually any shape can be created layer by layer from a Computer Aided Design (CAD) model. As opposed to the conventional Subtractive Manufacturing that uses cutting, drilling, milling, welding etc., 3D printing is a free-form fabrication process and does not require any of these processes. The 3D printed parts are lighter, require short lead times, less material and reduce environmental footprint of the manufacturing process; and is thus beneficial to the aerospace industry that pursues improvement in aircraft efficiency, fuel saving and reduction in air pollution. Additionally, 3D printing technology allows for creating geometries that would be impossible to make using moulds and the Subtractive Manufacturing of drilling/milling. 3D printing technology also has the potential to re-localize manufacturing as it allows for the production of products at the particular location, as and when required; and eliminates the need for shipping and warehousing of final products.

Using Unsupervised Learning for Regulating Deposition Speed During Robotic Wire Arc Additive Manufacturing

2021 ◽  
Author(s):  
Ashish Kulkarni ◽  
Prahar M. Bhatt ◽  
Alec Kanyuck ◽  
Satyandra K. Gupta
Keyword(s):  
Additive Manufacturing ◽  
Unsupervised Learning ◽  
Molten Metal ◽  
Length Variation ◽  
Bead Geometry ◽  
Layer By Layer ◽  
Arc Length ◽  
Regulation Scheme ◽  
Speed Regulation ◽  
Wire Arc Additive Manufacturing

Abstract Robotic Wire Arc Additive Manufacturing (WAAM) is the layer-by-layer deposition of molten metal to build a three-dimensional part. In this process, the fed metal wire is melted using an electric arc as a heat source. The process is sensitive to the arc conditions, such as arc length. While building WAAM parts, the metal beads overlap at corners causing material accumulation. Material accumulation is undesirable as it leads to uneven build height and process failures caused by arc length variation. This paper introduces a deposition speed regulation scheme to avoid the corner accumulation problem and build parts with uniform build height. The regulated speed has a complex relationship with the corner angle, bead geometry, and molten metal dynamics. So we need to train a model that can predict suitable speed regulations for corner angles encountered while building the part. We develop an unsupervised learning technique to characterize the uniformity of the bead profile of a WAAM built layer and check for anomalous bead profiles. We train a model using these results that can predict suitable speed regulation parameters for different corner angles. We test this model by building a WAAM part using our speed regulation scheme and validate if the built part has uniform build height and reduced corner defects.

Additive Manufacturing of Nickel-Based Super Alloys for Aero Engine Applications

2020 ◽  
pp. 48-70
Author(s):  
Raja A. ◽  
Mythreyi O. V. ◽  
Jayaganthan R.
Keyword(s):  
Additive Manufacturing ◽  
Complex Geometry ◽  
Source Parameters ◽  
Raw Material ◽  
Layer By Layer ◽  
Powder Bed ◽  
Complex Design ◽  
Direct Energy ◽  
Second Phases ◽  
Metal Addition

Ni based super alloys are widely used in engine turbines because of their proven performance at high temperatures. Manufacturing these parts by additive manufacturing (AM) methods provides researchers a lot of creative space for complex design to improve efficiency. Powder bed fusion (PBF) and direct energy deposition (DED) are the two most widely-used metal AM methods. Both methods are influenced by the source, parameters, design, and raw material. Selective laser melting is one of the laser-based PBF techniques to create small layer thickness and complex geometry with greater accuracy and properties. The layer-by-layer metal addition generates epitaxial growth and solidification in the built direction. There are different second phases in the Ni-based superalloys. This chapter details the micro-segregation of these particles and its influence on the microstructure, and mechanical properties are dependent on the process influencing parameters, the thermal kinetics during the process, and the post-processing treatments.

scholarly journals Analysis and characterization of additive manufacturing processes

2021 ◽  
Vol 13 (4) ◽  
pp. 167-180
Author(s):  
Andra TOFAN-NEGRU ◽  
Cristian BARBU ◽  
Amado STEFAN ◽  
Ioana-Carmen BOGLIS
Keyword(s):  
Additive Manufacturing ◽  
Complex Geometry ◽  
Cutting Tools ◽  
Manufacturing Processes ◽  
Layer By Layer ◽  
Advantages And Disadvantages ◽  
Finishing Processes ◽  
Short Time ◽  
Physical Phenomena ◽  
Am Processes

Recently, additive manufacturing (AM) processes have expanded rapidly in various fields of the industry because they offer design freedom, involve layer-by-layer construction from a computerized 3D model (minimizing material consumption), and allow the manufacture of parts with complex geometry (thus offering the possibility of producing custom parts). Also, they provide the advantage of a short time to make the final parts, do not involve the need for auxiliary resources (cutting tools, lighting fixtures or coolants) and have a low impact on the environment. However, the aspects that make these technologies not yet widely used in industry are poor surface quality of parts, uncertainty about the mechanical properties of products and low productivity. Research on the physical phenomena associated with additive manufacturing processes is necessary for proper control of the phenomena of melting, solidification, vaporization and heat transfer. This paper addresses the relevant additive manufacturing processes and their applications and analyzes the advantages and disadvantages of AM processes compared to conventional production processes. For the aerospace industry, these technologies offer possibilities for manufacturing lighter structures to reduce weight, but improvements in precision must be sought to eliminate the need for finishing processes.

scholarly journals Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing

Materials ◽  
2021 ◽  
Vol 14 (18) ◽  
pp. 5370
Author(s):  
Geir Langelandsvik ◽  
Odd M. Akselsen ◽  
Trond Furu ◽  
Hans J. Roven
Keyword(s):  
Aluminum Alloy ◽  
Additive Manufacturing ◽  
Alloy Composition ◽  
Layer By Layer ◽  
Alloy Development ◽  
And Performance ◽  
Crack Susceptibility ◽  
Wire Arc Additive Manufacturing ◽  
Further Development ◽  
Complex Parts

Processing of aluminum alloys by wire arc additive manufacturing (WAAM) gained significant attention from industry and academia in the last decade. With the possibility to create large and relatively complex parts at low investment and operational expenses, WAAM is well-suited for implementation in a range of industries. The process nature involves fusion melting of a feedstock wire by an electric arc where metal droplets are strategically deposited in a layer-by-layer fashion to create the final shape. The inherent fusion and solidification characteristics in WAAM are governing several aspects of the final material, herein process-related defects such as porosity and cracking, microstructure, properties, and performance. Coupled to all mentioned aspects is the alloy composition, which at present is highly restricted for WAAM of aluminum but received considerable attention in later years. This review article describes common quality issues related to WAAM of aluminum, i.e., porosity, residual stresses, and cracking. Measures to combat these challenges are further outlined, with special attention to the alloy composition. The state-of-the-art of aluminum alloy selection and measures to further enhance the performance of aluminum WAAM materials are presented. Strategies for further development of new alloys are discussed, with attention on the importance of reducing crack susceptibility and grain refinement.

scholarly journals Experimental Investigation on Mechanical Properties of Part Fabricated by Wire Arc Additive Manufacturing Process

2021 ◽  
Author(s):  
Vivek Kumar P ◽  
◽  
Soundrapandian E ◽  
Jenin Joseph A ◽  
Kanagarajan E ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Manufacturing Process ◽  
Three Dimensional ◽  
Casting Process ◽  
Significant Rise ◽  
Layer By Layer ◽  
Cnc Machine ◽  
Hardness Tester ◽  
Wire Arc Additive Manufacturing

Additive manufacturing process is a method of layer by layer joining of materials to create components from three-dimensional (3D) model data. After their introduction in the automotive sector a decade ago, it has seen a significant rise in research and growth. The Additive manufacturing is classified into different types based upon the energy source use in the fabrication process. In our project, we used self-build CNC machine that runs MACH3 software, as well as the MACH3 controller is used to control the welding torch motion for material addition through three axis movement (X, Y and Z). In the project we used ER70 S-6 weld wire for the fabrication and examined its microstructure and mechanical properties. Different layers of the specimen had different microstructures, according to microstructural studies of the product. Rockwell hardness tester used for testing hardness of the product. According to the observation of the part fabricated components using the Wire Arc Additive Manufacturing process outperformed the mechanical properties of mild steel casting process. The product fabricated by Wire Arc Additive Manufacturing process properties is superior to conventional casting process.

Spatial Iterative Learning Control for Multi-material Three-Dimensional Structures

2020 ◽  
Vol 1 (1) ◽  
Author(s):  
Zahra Afkhami ◽  
Christopher Pannier ◽  
Leontine Aarnoudse ◽  
David Hoelzle ◽  
Kira Barton
Keyword(s):  
Additive Manufacturing ◽  
Iterative Learning Control ◽  
Initial Conditions ◽  
Three Dimensional ◽  
Single Layer ◽  
Learning Control ◽  
Iterative Learning ◽  
Layer By Layer ◽  
Additive Process ◽  
Jet Printing

Abstract Iterative learning control (ILC) is a powerful technique to regulate repetitive systems. Additive manufacturing falls into this category by nature of its repetitive action in building three-dimensional structures in a layer-by-layer manner. In literature, spatial ILC (SILC) has been used in conjunction with additive processes to regulate single-layer structures with only one class of material. However, SILC has the unexplored potential to regulate additive manufacturing structures with multiple build materials in a three-dimensional fashion. Estimating the appropriate feedforward signal in these structures can be challenging due to iteration varying initial conditions, system parameters, and surface interaction dynamics in different layers of multi-material structures. In this paper, SILC is used as a recursive control strategy to iteratively construct the feedforward signal to improve part quality of 3D structures that consist of at least two materials in a layer-by-layer manner. The system dynamics are approximated by discrete 2D spatial convolution using kernels that incorporate in-layer and layer-to-layer variations. We leverage the existing SILC models in literature and extend them to account for the iteration varying uncertainties in the plant model to capture a more reliable representation of the multi-material additive process. The feasibility of the proposed diagonal framework was demonstrated using simulation results of an electrohydrodynamic jet printing (e-jet) printing process.

Sign in / Sign up

Export Citation Format

Share Document