Wire + Arc Additive Manufacturing of Metals

2020 ◽  
pp. 106-126
Author(s):  
Krishna Kishore Mugada ◽  
Aravindan Sivanandam ◽  
Ravi Kumar Digavalli
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Manufacturing Sector ◽  
Manufacturing Processes ◽  
Deposition Rates ◽  
Direct Energy Deposition ◽  
Powder Bed ◽  
Direct Energy ◽  
Wire Arc Additive Manufacturing ◽  
Binder Jetting

Wire + Arc additive manufacturing (WAAM) processes have become popular because of their proven capabilities to produce large metallic components with high deposition rates (promoted by arc-based processes) compared to conventional additive manufacturing processes such as powder bed fusion, binder jetting, direct energy deposition, etc. The applications of WAAM processes were constantly increasing in the manufacturing sector, which necessitates an understanding of the process capability to various metals. This chapter outlines the significant outcomes of the WAAM process for most of the engineering metals in terms of microstructure and mechanical properties. Discussion on various defects associated with the processed components is also presented. Potential application of WAAM for different metals such as aluminum and its alloys, titanium, and steels was discussed. The research indicates that the components manufactured by the WAAM process have significant microstructural changes and improved mechanical properties.

scholarly journals Geometry and Distortion Prediction of Multiple Layers for Wire Arc Additive Manufacturing with Artificial Neural Networks

2021 ◽  
Vol 11 (10) ◽  
pp. 4694
Author(s):  
Christian Wacker ◽  
Markus Köhler ◽  
Martin David ◽  
Franziska Aschersleben ◽  
Felix Gabriel ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Welding Process ◽  
High Energy ◽  
Welding Distortion ◽  
Direct Energy Deposition ◽  
Direct Energy ◽  
Industrial Use ◽  
Artificial Neural ◽  
Artificial Neural Network Ann ◽  
Wire Arc Additive Manufacturing

Wire arc additive manufacturing (WAAM) is a direct energy deposition (DED) process with high deposition rates, but deformation and distortion can occur due to the high energy input and resulting strains. Despite great efforts, the prediction of distortion and resulting geometry in additive manufacturing processes using WAAM remains challenging. In this work, an artificial neural network (ANN) is established to predict welding distortion and geometric accuracy for multilayer WAAM structures. For demonstration purposes, the ANN creation process is presented on a smaller scale for multilayer beads on plate welds on a thin substrate sheet. Multiple concepts for the creation of ANNs and the handling of outliers are developed, implemented, and compared. Good results have been achieved by applying an enhanced ANN using deformation and geometry from the previously deposited layer. With further adaptions to this method, a prediction of additive welded structures, geometries, and shapes in defined segments is conceivable, which would enable a multitude of applications for ANNs in the WAAM-Process, especially for applications closer to industrial use cases. It would be feasible to use them as preparatory measures for multi-segmented structures as well as an application during the welding process to continuously adapt parameters for a higher resulting component quality.

Anwendungszentrum für additive Fertigung/Center for Applied Additive Manufacturing – Influence of process parameters during high-speed laser direct energy deposition

2021 ◽  
Vol 111 (06) ◽  
pp. 368-371
Author(s):  
Sebastian Greco ◽  
Marc Schmidt ◽  
Benjamin Kirsch ◽  
Jan C. Aurich
Keyword(s):  
Additive Manufacturing ◽  
High Speed ◽  
Energy Deposition ◽  
Influence Of Process Parameters ◽  
Direct Energy Deposition ◽  
Additive Fertigung ◽  
Powder Bed ◽  
High Productivity ◽  
Direct Energy ◽  
Near Net Shape

Additive Fertigungsverfahren zeichnen sich durch die Möglichkeit der endkonturnahen Fertigung komplexer Geometrien aus. Die geringe Produktivität etablierter Verfahren wie etwa dem Pulverbettverfahren hemmen aktuell den wirtschaftlichen Einsatz additiver Fertigung. Das Hochgeschwindigkeits-Laserauftragschweißen (HLA) soll durch deutlich erhöhte Auftragsraten und somit bisher unerreicht hoher Produktivität bei der additiven Fertigung dazu beitragen, deren Wirtschaftlichkeit zu steigern.   Additive manufacturing enables the near-net-shape production of complex geometries. The low productivity of established processes such as powder bed processes is currently limiting the economic use of additive manufacturing. High-speed laser direct energy deposition (HS LDED) is expected to improve the economic efficiency of additive manufacturing by significantly increasing deposition rates and thus previously unattained high productivity.

Review on Powder-Bed Laser Additive Manufacturing of Inconel 718 Parts

2015 ◽  
Author(s):  
Xiaoqing Wang ◽  
Xibing Gong ◽  
Kevin Chou
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Literature Review ◽  
Selective Laser Melting ◽  
Inconel 718 ◽  
Manufacturing Processes ◽  
Laser Melting ◽  
Laser Additive Manufacturing ◽  
Powder Bed ◽  
General Aspects

This study presents a thorough literature review on the powder-bed laser additive manufacturing processes such as selective laser melting (SLM) of Inconel 718 parts. The paper first introduces the general aspects of powder-bed laser additive manufacturing and then discusses the unique characteristics and advantages of SLM. Moreover, the bulk of this study includes extensive discussions of microstructures and mechanical properties, together with the application ranges, of Inconel 718 parts fabricated by SLM.

scholarly journals Hybrid additive manufacturing of steels and alloys

2020 ◽  
Vol 7 ◽  
pp. 6
Author(s):  
Vladimir V. Popov ◽  
Alexander Fleisher
Keyword(s):  
Additive Manufacturing ◽  
Energy Deposition ◽  
Modern Trend ◽  
Production Chain ◽  
Direct Energy Deposition ◽  
Powder Bed ◽  
Direct Energy ◽  
Manufacturing Techniques ◽  
Traditional Manufacturing

Hybrid additive manufacturing is a relatively modern trend in the integration of different additive manufacturing techniques in the traditional manufacturing production chain. Here the AM-technique is used for producing a part on another substrate part, that is manufactured by traditional manufacturing like casting or milling. Such beneficial combination of additive and traditional manufacturing helps to overcome well-known issues, like limited maximum build size, low production rate, insufficient accuracy, and surface roughness. The current paper is devoted to the classification of different approaches in the hybrid additive manufacturing of steel components. Additional discussion is related to the benefits of Powder Bed Fusion (PBF) and Direct Energy Deposition (DED) approaches for hybrid additive manufacturing of steel components.

scholarly journals Sensor-Based Additive Manufacturing Technologies

2021 ◽  
Vol 12 (3) ◽  
pp. 3513-3521
Keyword(s):  
Additive Manufacturing ◽  
Wearable Sensors ◽  
Sensor Technology ◽  
Layer By Layer ◽  
Environmental Sensors ◽  
Direct Energy Deposition ◽  
Powder Bed ◽  
Direct Energy ◽  
Building Components ◽  
Manufacturing Technologies

Additive manufacturing is the term that uses the CAD data to build components layer by layer; it is also termed layered manufacturing or 3D printing. The major advantage of additive manufacturing is the capability of building components without the use of molds or tools. Five major categories of AM processes include Powder Bed Fusion (PBF), Direct Energy Deposition (DED), Material Jetting (MJ), Binder Jetting (BJ), and Sheet Lamination (SL). The sensor may be defined as a device that responds to a physical stimulus and transmits a resulting impulse. Sensor technology has been widely adopted in advanced manufacturing, aerospace, biomedical and robotic applications. Commonly used sensors are temperature sensors, strain sensors, biosensors, environmental sensors, and wearable sensors, etc. Additive manufacturing technologies can fabricate sensors and microfluidic devices with less labor. This paper focuses on various sensors developed by additive manufacturing processes, and their practical application for the particular purpose is reviewed.

Review on powder-bed laser additive manufacturing of Inconel 718 parts

2016 ◽  
Vol 231 (11) ◽  
pp. 1890-1903 ◽  
Author(s):  
Xiaoqing Wang ◽  
Xibing Gong ◽  
Kevin Chou
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Literature Review ◽  
Selective Laser Melting ◽  
Inconel 718 ◽  
Manufacturing Processes ◽  
Laser Melting ◽  
Laser Additive Manufacturing ◽  
Powder Bed ◽  
General Aspects

This study presents a thorough literature review on the powder-bed laser additive manufacturing processes such as selective laser melting of Inconel 718 parts. This article first introduces the general aspects of powder-bed laser additive manufacturing and then discusses the unique characteristics and advantages of selective laser melting. The bulk of this study includes extensive discussions of microstructures and mechanical properties, together with the application ranges of Inconel 718 parts fabricated by selective laser melting.

scholarly journals Additive Manufacturing Processes in Medical Applications

Materials ◽  
2021 ◽  
Vol 14 (1) ◽  
pp. 191
Author(s):  
Mika Salmi
Keyword(s):  
Additive Manufacturing ◽  
Energy Deposition ◽  
Manufacturing Processes ◽  
Medical Applications ◽  
Powder Bed Fusion ◽  
Powder Bed ◽  
Material Extrusion ◽  
Fusion Material ◽  
Directed Energy ◽  
Binder Jetting

Additive manufacturing (AM, 3D printing) is used in many fields and different industries. In the medical and dental field, every patient is unique and, therefore, AM has significant potential in personalized and customized solutions. This review explores what additive manufacturing processes and materials are utilized in medical and dental applications, especially focusing on processes that are less commonly used. The processes are categorized in ISO/ASTM process classes: powder bed fusion, material extrusion, VAT photopolymerization, material jetting, binder jetting, sheet lamination and directed energy deposition combined with classification of medical applications of AM. Based on the findings, it seems that directed energy deposition is utilized rarely only in implants and sheet lamination rarely for medical models or phantoms. Powder bed fusion, material extrusion and VAT photopolymerization are utilized in all categories. Material jetting is not used for implants and biomanufacturing, and binder jetting is not utilized for tools, instruments and parts for medical devices. The most common materials are thermoplastics, photopolymers and metals such as titanium alloys. If standard terminology of AM would be followed, this would allow a more systematic review of the utilization of different AM processes. Current development in binder jetting would allow more possibilities in the future.

Metal Binder Jetting Additive Manufacturing: A Literature Review

2020 ◽  
Vol 142 (9) ◽  
Author(s):  
Ming Li ◽  
Wenchao Du ◽  
Alaa Elwany ◽  
Zhijian Pei ◽  
Chao Ma
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Related Factors ◽  
Powder Bed ◽  
Metal Binder ◽  
Powder Packing ◽  
Superior Mechanical Properties ◽  
Directed Energy ◽  
Reported Data ◽  
Binder Jetting

Abstract Binder jetting is an additive manufacturing process utilizing a liquid-based binding agent to selectively join the material in a powder bed. It is capable of manufacturing complex-shaped parts from a variety of materials including metals, ceramics, and polymers. This paper provides a comprehensive review on currently available reports on metal binder jetting from both academia and industry. Critical factors and their effects in metal binder jetting are reviewed and divided into two categories, namely material-related factors and process-related parameters. The reported data on density, dimensional and geometric accuracy, and mechanical properties achieved by metal binder jetting are summarized. With parameter optimization and a suitable sintering process, ten materials have been proven to achieve a relative density of higher than 90%. Indepth discussion is provided regarding densification as a function of various attributes of powder packing, printing, and post-processing. A few grades of stainless steel obtained equivalent or superior mechanical properties compared to cold working. Although binder jetting has gained its popularity in the past several years, it has not been sufficiently studied compared with other metal additive manufacturing (AM) processes such as powder bed fusion and directed energy deposition. Some aspects that need further research include the understanding of powder spreading process, binder-powder interaction, and part shrinkage.

Wire Arc Additive Manufacturing of Stainless Steels: A Review

2020 ◽  
Vol 10 (5) ◽  
pp. 1563 ◽  
Author(s):  
Wanwan Jin ◽  
Chaoqun Zhang ◽  
Shuoya Jin ◽  
Yingtao Tian ◽  
Daniel Wellmann ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Residual Stress ◽  
Stainless Steel ◽  
Additive Manufacturing ◽  
Process Parameters ◽  
Stainless Steels ◽  
Heat Treatments ◽  
Physical Metallurgy ◽  
Deposition Rates ◽  
Wire Arc Additive Manufacturing

Wire arc additive manufacturing (WAAM) has been considered as a promising technology for the production of large metallic structures with high deposition rates and low cost. Stainless steels are widely applied due to good mechanical properties and excellent corrosion resistance. This paper reviews the current status of stainless steel WAAM, covering the microstructure, mechanical properties, and defects related to different stainless steels and process parameters. Residual stress and distortion of the WAAM manufactured components are discussed. Specific WAAM techniques, material compositions, process parameters, shielding gas composition, post heat treatments, microstructure, and defects can significantly influence the mechanical properties of WAAM stainless steels. To achieve high quality WAAM stainless steel parts, there is still a strong need to further study the underlying physical metallurgy mechanisms of the WAAM process and post heat treatments to optimize the WAAM and heat treatment parameters and thus control the microstructure. WAAM samples often show considerable anisotropy both in microstructure and mechanical properties. The new in-situ rolling + WAAM process is very effective in reducing the anisotropy, which also can reduce the residual stress and distortion. For future industrial applications, fatigue properties, and corrosion behaviors of WAAMed stainless steels need to be deeply studied in the future. Additionally, further efforts should be made to improve the WAAM process to achieve faster deposition rates and better-quality control.

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