Academic literature on the topic 'Additive Manufacturing, CAM, WAAM, Welding'
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Journal articles on the topic "Additive Manufacturing, CAM, WAAM, Welding"
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Reimann, Jan, Philipp Henckell, Yarop Ali, Stefan Hammer, Alexander Rauch, Jörg Hildebrand, and Jean Pierre Bergmann. "Production of Topology-optimised Structural Nodes Using Arc-based, Additive Manufacturing with GMAW Welding Process." Journal of Civil Engineering and Construction 10, no. 2 (May 15, 2021): 101–7. http://dx.doi.org/10.32732/jcec.2021.10.2.101.
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The desire to generate a stress optimised structural node with maximum stability is often coupled with the goal of low manufacturing costs and an adapted and minimal use of material. The complex, three-dimensional free-form structures, which are created by means of topology-optimisation, are only partially suitable for conventional manufacturing. The wire arc additive manufacturing (WAAM), by means of arc welding processes, offer a cost-effective and flexible possibility for the individual production of complex, metallic components. Gas metal arc welding (GMAW) is particularly suitable to produce large-volume, load-bearing structures due to build-up rates of up to 5 kg/h. The generation of strength and stiffness adapted support structures by means of the numerical simulation method of topology-optimisation was investigated in this study to generate topology-optimised structural nodes. The resulting node is transferred into a robot path using CAD/CAM software and manufactured from the filler material G4Si1 using WAAM with the GMAW process. Based on the boundary conditions of the WAAM process, the path planning and thus the manufacturability of the topology-optimised supporting structure nodes is evaluated and verified using a sample structure made of the welding filler material G4Si1. Depending on the path planning, an improvement of the mechanical properties could be achieved, due to changes in t8/5 times.
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Rauch, Matthieu, Jean-Yves Hascoet, and Vincent Querard. "A Multiaxis Tool Path Generation Approach for Thin Wall Structures Made with WAAM." Journal of Manufacturing and Materials Processing 5, no. 4 (November 30, 2021): 128. http://dx.doi.org/10.3390/jmmp5040128.
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Wire Arc Additive Manufacturing (WAAM) has emerged over the last decade and is dedicated to the realization of high-dimensional parts in various metallic materials. The usual process implementation consists in associating a high-performance welding generator as heat source, a NC controlled 6 or 8 degrees (for example) of freedom robotic arm as motion system and welding wire as feedstock. WAAM toolpath generation methods, although process specific, can be based on similar approaches developed for other processes, such as machining, to integrate the process data into a consistent technical data environment. This paper proposes a generic multiaxis tool path generation approach for thin wall structures made with WAAM. At first, the current technological and scientific challenges associated to CAD/CAM/CNC data chains for WAAM applications are introduced. The focus is on process planning aspects such as non-planar non-parallel slicing approaches and part orientation into the working space, and these are integrated in the proposed method. The interest of variable torch orientation control for complex shapes is proposed, and then, a new intersection crossing tool path method based on Design For Additive Manufacturing considerations is detailed. Eventually, two industrial use cases are introduced to highlight the interest of this approach for realizing large components.
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Dugar, Jaka, Awais Ikram, Damjan Klobčar, and Franci Pušavec. "Sustainable Hybrid Manufacturing of AlSi5 Alloy Turbine Blade Prototype by Robotic Direct Energy Layered Deposition and Subsequent Milling: An Alternative to Selective Laser Melting?" Materials 15, no. 23 (December 3, 2022): 8631. http://dx.doi.org/10.3390/ma15238631.
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Additive technologies enable the flexible production through scalable layer-by-layer fabrication of simple to intricate geometries. The existing 3D-printing technologies that use powders are often slow with controlling parameters that are difficult to optimize, restricted product sizes, and are relatively expensive (in terms of feedstock and processing). This paper presents the development of an alternative approach consisting of a CAD/CAM + combined wire arc additive-manufacturing (WAAM) hybrid process utilizing the robotic MIG-based weld surfacing and milling of the AlSi5 aluminum alloy, which achieves sustainably high productivity via structural alloys. The feasibility of this hybrid approach was analyzed on a representative turbine blade piece. SprutCAM suite was utilized to identify the hybrid-manufacturing parameters and virtually simulate the processes. This research provides comprehensive experimental data on the optimization of cold metal transfer (CMT)–WAAM parameters such as the welding speed, current/voltage, wire feed rate, wall thickness, torch inclination angle (shift/tilt comparison), and deposit height. The multi-axes tool orientation and robotic milling strategies, i.e., (a) the side surface from rotational one-way bottom-up and (b) the top surface in a rectangular orientation, were tested in virtual CAM environments and then adopted during the prototype fabrication to minimize the total fabrication time. The effect of several machining parameters and robotic stiffness (during WAAM + milling) were also investigated. The mean deviation for the test piece’s tolerance between the virtual processing and experimental fabrication was −0.76 mm (approx.) at a standard deviation of 0.22 mm assessed by 3D scanning. The surface roughness definition Sa in the final WAAM pass corresponds to 36 µm, which was lowered to 14.3 µm after milling, thus demonstrating a 55% improvement through the robotic comminution. The tensile testing at 0° and 90° orientations reported fracture strengths of 159 and 161.3 MPa, respectively, while the yield stress and reduced longitudinal (0°) elongations implied marginally better toughness along the WAAM deposition axes. The process sustainability factors of hybrid production were compared with Selective Laser Melting (SLM) in terms of the part size freedom, processing costs, and fabrication time with respect to tight design tolerances. The results deduced that this alternative hybrid-processing approach enables an economically viable, resource/energy feasible, and time-efficient method for the production of complex parts in contrast to the conventional additive technologies, i.e., SLM.
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Mu, Haochen, Joseph Polden, Yuxing Li, Fengyang He, Chunyang Xia, and Zengxi Pan. "Layer-by-layer model-based adaptive control for wire arc additive manufacturing of thin-wall structures." Journal of Intelligent Manufacturing 33, no. 4 (March 10, 2022): 1165–80. http://dx.doi.org/10.1007/s10845-022-01920-5.
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AbstractImproving the geometric accuracy of the deposited component is essential for the wider adoption of wire arc additive manufacturing (WAAM) in industries. This paper introduces an online layer-by-layer controller that operates robustly under various welding conditions to improve the deposition accuracy of the WAAM process. Two control strategies are proposed and evaluated in this work: A PID algorithm and a multi-input multi-output model-predictive control (MPC) algorithm. After each layer of deposition, the deposited geometry is measured using a laser scanner. These measurements are compared against the CAD model, and geometric errors are then compensated by the controller, which generates a new set of welding parameters for the next layer. The MPC algorithm, combined with a linear autoregressive (ARX) modelling process, updates welding parameters between successive layers by minimizing a cost function based on sequences of input variables and predicted responses. Weighting coefficients of the ARX model are trained iteratively throughout the manufacturing process. The performance of the designed control architecture is investigated through both simulation and experiments. Results show that the real-time control performance is improved by increasing the complexity of implemented control algorithm: controlled geometric fluctuations in the test component were reduced by 200% whilst maintaining fluctuations within a 3 mm limit under various welding conditions. In addition, the adaptiveness of designed control strategy is verified by accurately controlling the fabrication of a part with complex geometry.
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Anikin, P. S., G. M. Shilo, R. A. Kulykovskyi, and D. E. Molochkov. "Automation control system of 3d printing robotic platform with implemented wire + arc welding technology." Electrical Engineering and Power Engineering, no. 4 (December 30, 2020): 35–48. http://dx.doi.org/10.15588/1607-6761-2020-4-4.
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Purpose. Development of the robotic platform automated control system architecture, development of the software control algorithm.
Methodology. To implement the algorithm of the control program, computer modeling of thermal regimes in CAE systems is used. The basic parameters of the single layer printing technique were obtained by experimental use of the wire plus arc additive manufacturing (WAAM) technology.
Findings. Requirements for manufacturability and printing quality of the manufactured parts were defined in the form of geometric dimensions, surface waviness, parameters of the desired microstructure state, residual stresses, maintaining of the optimal manufacturing speed. Based on the requirements of manufacturability analysis, an algorithm for the control program was developed. Robotic platform automated control system architecture with feedback device for the thermal mode control, parameters of the geometrical form of the manufactured part and weld pool were developed. Three -level hierarchical model, which gives an ability to consider in the process of 3D printing each level individually in terms of welding bead, layer and wall, was developed. The input data for the operation of the automated control system of the robotic platform using the technology of electric arc welding are determined. Basic geometrical parameters and the simple welding bead and the methods of overlapping of two or more beads were shown. Critical differences between ideal and real welding overlapping models were considered for necessity of taking into account whilst generating robot control software. Analysis of the possibilities for the CAE simulation of the three-dimensional printing using wire plus arc additive manufacturing technology is performed to determine the influence of the temperature parameters, mechanical loads, toolpath change, and based on the data obtained, it became possible to determine residual stresses and defects in manufactured parts.
Originality. Robotic platform automated control system architecture with feedback device for the control of thermal mode, parameters of the geometrical form of the manufactured part and weld pool was developed. Three-level hierarchical model for the wire plus arc additive manufacturing (WAAM) technology was created. Software control algorithm which provides an opportunity to improve geometrical and mechanical properties of the manufactured parts was developed.
Practical value. Development of an automated control system for 3D printing robotic platform with WAAM implemented technology, which will provide an opportunity for increase in the printing accuracy of the manufactured parts and will help to reduce manufacturing time.
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Silwal, Bishal, Niraj Pudasaini, Sougata Roy, Anthony B. Murphy, Andrzej Nycz, and Mark W. Noakes. "Altering the Supply of Shielding Gases to Fabricate Distinct Geometry in GMA Additive Manufacturing." Applied Sciences 12, no. 7 (April 6, 2022): 3679. http://dx.doi.org/10.3390/app12073679.
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Wire arc additive manufacturing (WAAM) is the process by which large, metallic structures are built, layer-by-layer, using a welding arc to melt wire feedstock. In this process, the proper selection of the shielding gas plays a vital role in the achievement of structurally acceptable part geometries and quality surface finishes. In this study, the authors used either a ternary mix (He, Ar and CO2) or a binary mix (Ar and CO2) of shielding gases to deposit wall geometries using an open loop-controlled WAAM system developed at Oak Ridge National Laboratory’s Manufacturing Demonstration Facility. The binary blend produced a wider and shorter geometry, while the ternary blend resulted in a narrower build that was more equivalent to the CAD geometry. The data indicated that the binary blend provided a higher oxygen concentration in the weld as compared to that of the ternary blend. The results imply that the arc characteristics and heat input had a significantly higher impact on the weld penetration than the surface tension effect of surface active elements. This was further verified by developing and applying a high-fidelity computational fluid dynamics (CFD) model of the thermophysical properties of gas mixtures. The results from the model showed that, while the influence of increased oxygen concentration on the surface tension for the binary blend led to a deeper penetration, the ternary blend gave rise to heat flux to the workpiece.
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Sarma, Ritam, Sajan Kapil, and Shrikrishna N. Joshi. "Build Strategies Based on Substrate Utilization for 3-Axis Hybrid Wire Arc Additive Manufacturing Process." Advances in Materials Science and Engineering 2022 (May 30, 2022): 1–21. http://dx.doi.org/10.1155/2022/4988301.
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The hybrid wire arc additive manufacturing (H-WAAM) process is one of the prominent methods for realizing large near-net-shaped metallic objects. In this process, a CAD model of the component is sliced into a set of 2D contours followed by the generation of toolpaths. An arc welding torch then follows these toolpaths for adding material over a substrate to realize the near-net shape of the object. These near-net-shaped objects are then followed by a machining operation to convert them into a fully functional part. It is always anticipated that the near-net shape of an object is produced quickly and upholds a high geometrical accuracy. Conventionally, the deposition rate is increased to reduce the build time but with a compromisation in the geometrical accuracy and material integrity. Therefore, in this work, the authors have investigated three substrate utilization methods, viz., (i) reusable substrate, (ii) embedded substrate, and (iii) integrated substrate to achieve the same goal. The build strategies for these three substrate utilization methods are illustrated through several examples. Also, a case study was performed for fabricating an impeller-like structure through a 3-axis H-WAAM setup. It has been observed that the embedded substrate method exhibits superior geometrical accuracy and takes less time to build the part as compared to other methods. A maximum of 64.34% of the material and 89.17% of build time is saved by adopting proposed build strategies compared with the traditional subtractive process.
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Wang, Xiaolong, Aimin Wang, Kaixiang Wang, and Yuebo Li. "Process stability for GTAW-based additive manufacturing." Rapid Prototyping Journal 25, no. 5 (June 10, 2019): 809–19. http://dx.doi.org/10.1108/rpj-02-2018-0046.
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Abstract Purpose Traditional gas tungsten arc welding (GTAW) and GTAW-based wire and arc additive manufacturing (WAAM) are notably different. These differences are crucial to the process stability and surface quality in GTAW WAAM. This paper addresses special characteristics and the process control method of GTAW WAAM. The purpose of this paper is to improve the process stability with sensor information fusion in omnidirectional GTAW WAAM process. Design/methodology/approach A wire feed strategy is proposed to achieve an omnidirectional GTAW WAAM process. Thus, a model of welding voltage with welding current and arc length is established. An automatic control system fit to the entire GTAW WAAM process is established using both welding voltage and welding current. The effect of several types of commonly used controllers is examined. To assess the validity of this system, an arc length step experiment, various wire feed speed experiments and a square sample experiment were performed. Findings The research findings show that the resented wire feed strategy and arc length control system can effectively guarantee the stability of the GTAW WAAM process. Originality/value This paper tries to make a foundation work to achieve omnidirectional welding and process stability of GTAW WAAM through wire feed geometry analysis and sensor information fusion control model. The proposed wire feed strategy is implementable and practical, and a novel sensor fusion control method has been developed in the study for varying current GTAW WAAM process.
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Klobčar, Damjan, Maja Lindič, and Matija Bušić. "Wire arc additive manufacturing of mild steel." Materials and Geoenvironment 65, no. 4 (December 1, 2018): 179–86. http://dx.doi.org/10.2478/rmzmag-2018-0015.
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AbstractThis paper presents an overview of additive manufacturing technologies for production of metal parts. A special attention is set to wire arc additive manufacturing (WAAM) technologies, which include MIG/MAG welding, TIG welding and plasma welding. Their advantages compared to laser or electron beam technologies are lower investment and operational costs. However, these processes have lower dimensional accuracy of produced structures. Owing to special features and higher productivity, the WAAM technologies are more suitable for production of bigger parts. WAAM technology has been used together with welding robot and a cold metal transfer (CMT) power source. Thin walls have been produced using G3Si1 welding wire. The microstructure and hardness of produced structures were analysed and measured. A research was done to determine the optimal welding parameters for production of thin walls with smooth surface. A SprutCAM software was used to make a code for 3D printing of sample part.
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Li, Johnnieew Zhong, Mohd Rizal Alkahari, Nor Ana Binti Rosli, Rafidah Hasan, Mohd Nizam Sudin, and Faiz Redza Ramli. "Review of Wire Arc Additive Manufacturing for 3D Metal Printing." International Journal of Automation Technology 13, no. 3 (May 5, 2019): 346–53. http://dx.doi.org/10.20965/ijat.2019.p0346.
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Wire arc additive manufacturing (WAAM) is a crucial technique in the fabrication of 3D metallic structures. It is increasingly being used worldwide to reduce costs and time. Generally, AM technology is used to overcome the limitations of traditional subtractive manufacturing (SM) for fabricating large-scale components with lower buy-to-fly ratios. There are three heat sources commonly used in WAAM: metal inert gas welding (MIG), tungsten inert gas welding (TIG), and plasma arc welding (PAW). MIG is easier and more convenient than TIG and PAW because it uses a continuous wire spool with the welding torch. Unlike MIG, tungsten inert gas welding (TIG) and plasma arc welding (PAW) need an external wire feed machine to supply the additive materials. WAAM is gaining popularity in the fabrication of 3D metal components, but the process is hard to control due to its inherent residual stress and distortion, which are generated by the high thermal input from its heat sources. Distortion and residual stress are always a challenge for WAAM because they can affect the component’s geometric accuracy and drastically degrade the mechanical properties of the components. In this paper, wire-based and wire arc technology processes for 3D metal printing, including their advantages and limitations are reviewed. The optimization parametric study and modification of WAAM to reduce both residual stress and distortion are tabulated, summarized, and discussed.
Dissertations / Theses on the topic "Additive Manufacturing, CAM, WAAM, Welding"
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Graf, Marcel, Andre Hälsig, Kevin Höfer, Birgit Awiszus, and Peter Mayr. "Thermo-Mechanical Modelling of Wire-Arc Additive Manufacturing (WAAM) of Semi-Finished Products." MDPI AG, 2018. https://monarch.qucosa.de/id/qucosa%3A33161.
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Additive manufacturing processes have been investigated for some years, and are commonly used industrially in the field of plastics for small- and medium-sized series. The use of metallic deposition material has been intensively studied on the laboratory scale, but the numerical prediction is not yet state of the art. This paper examines numerical approaches for predicting temperature fields, distortions, and mechanical properties using the Finite Element (FE) software MSC Marc. For process mapping, the filler materials G4Si1 (1.5130) for steel, and AZ31 for magnesium, were first characterized in terms of thermo-physical and thermo-mechanical properties with process-relevant cast microstructure. These material parameters are necessary for a detailed thermo-mechanical coupled Finite Element Method (FEM). The focus of the investigations was on the numerical analysis of the influence of the wire feed (2.5–5.0 m/min) and the weld path orientation (unidirectional or continuous) on the temperature evolution for multi-layered walls of miscellaneous materials. For the calibration of the numerical model, the real welding experiments were carried out using the gas-metal arc-welding process—cold metal transfer (CMT) technology. A uniform wall geometry can be produced with a continuous welding path, because a more homogeneous temperature distribution results.
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Karlsson, Mattias, and Axel Magnusson. "Wire and Arc Additive Manufacturing : Pre printing strategy for torque arm." Thesis, Luleå tekniska universitet, Institutionen för teknikvetenskap och matematik, 2020. http://urn.kb.se/resolve?urn=urn:nbn:se:ltu:diva-79176.
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Wire and Arc Additive Manufacturing (WAAM) is a novel Additive manufacturing method. It is a high deposition rate process which can be suitable for producing low to medium quantities of medium to large sized components. Because it is such a novel method, there are still somechallenges to solve for the method to be useful. This project have been focusing on how to dealwith these challenges and how to manufacture a torque arm with WAAM. This includes the process on how to go from a CAD model to a printed product. Tests have been done during the project parallel with the design of the torque arm. The design have been modied according to the results from the tests. The result of the project was a more specic description how the softwares can be used to optimizethe process for a successful print. The used slicing software, Simplify3D, have some limitations and other options should be considered. Some limitations for the part design have been identied and some known challenges have been solved. The torque arm was successfully printed but with more time and refinement, the added offset could be reduced. The process was time consuming and needs to be more automated in the future. Some proposals on what should be further tested and evaluated is also stated in this report.
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Berger, Maik. "10. SAXON SIMULATION MEETING : Präsentationen und Vorträge des 10. Anwendertreffens am 22. März 2018 an der Technischen Universität Chemnitz." Technische Universität Chemnitz, 2018. https://monarch.qucosa.de/id/qucosa%3A21380.
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Von der Professur Montage- und Handhabungstechnik der Fakultät für Maschinenbau der Technischen Universität Chemnitz wird seit 2009 das jährliche Simulationsanwendertreffen SAXSIM organisiert. Ausgewählte Beiträge werden in Form eines Tagungsbandes veröffentlicht. Das 10. Anwendertreffen SAXSIM fand am 22.03.2018 an der TU Chemnitz statt.The Chair of Assembly and Handling Technology, which belongs to the Faculty of Mechanical Engineering, has organized the annual simulation user meeting SAXSIM since 2009. Select contributions will be published in conference proceedings. The 10th SAXSIM user meeting took place at Technische Universität Chemnitz on March 22, 2018.
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Berger, Maik. "11. SAXON SIMULATION MEETING : Präsentationen und Vorträge des 11. Anwendertreffens am 26. März 2019 an der Technischen Universität Chemnitz." Technische Universität Chemnitz, 2019. https://monarch.qucosa.de/id/qucosa%3A34090.
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Von der Professur Montage- und Handhabungstechnik der Fakultät für Maschinenbau der Technischen Universität Chemnitz wird seit 2009 das jährliche Simulationsanwendertreffen SAXSIM organisiert. Ausgewählte Beiträge werden in Form eines Tagungsbandes veröffentlicht. Das 11. Anwendertreffen SAXSIM fand am 26.03.2019 an der TU Chemnitz statt.The Chair of Assembly and Handling Technology, which belongs to the Faculty of Mechanical Engineering, has organized the annual simulation user meeting SAXSIM since 2009. Select contributions will be published in conference proceedings. The 11th SAXSIM user meeting took place at Technische Universität Chemnitz on March 26, 2019.
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Venturini, Giuseppe. "Architecture, design and implementation of CAM software for Wire and Arc Additive Manufacturing." Doctoral thesis, 2019. http://hdl.handle.net/2158/1153779.
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This PhD thesis deals with the automatic deposition toolpath generation for WAAM (Wire Arc Additive Manufacturing). WAAM is an Additive Manufacturing technology for metal components that uses an electric arc to melt a continuosly fed wire thus depositing a bead on a metal plate. It is a very primising technology since it is suitable to build parts large up to meters with an high deposition rate. However, automatic software to calculate the deposition toolpath for a part taking the CAD model as input is not easily available. Therefore, the PhD activity focused on the development of toolpath calculation algorithms for the generation of both three and five axes deposition toolpath. Moreover, the design and construction processes of a five axis machine to test the deposition toolpaths is presented together with a device able to reconstruct the geometry of the deposited material during the deposition phase that in the future could be used to obtain a numerical control with a closed loop approach able to automatically correct the deposition defects.
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Rodrigues, Tiago Miguel André. "Wire and arc additive manufacturing: equipment development and parts characterization." Master's thesis, 2018. http://hdl.handle.net/10362/63263.
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Wire and arc additive manufacturing (WAAM) is finding applications in different industrial sectors where it shows to be competitive compared to laser based additive manufacturing technologies. Two major advantages are associated to WAAM: it is a low capital investment technology with reduced running and maintenance costs and allows to manufacture parts with insipient or no porosities.
This study aimed at testing and validating a three-axis positioning system designed and manufactured at Mechanical Technology Group of Mechanical and Industrial Engineering Department at Nova University.
The major characteristics of the developed system are the following: 4.5 m3 working space, a maximum travel speed of 59 mm/s for the X and Y axes and of 2 mm/s for the Z axis. A maximum positional deviation of 0.02 mm, a minimal travel speed deviation of 0.24 mm/s and a displacement of 0.2 mm of the welding torch due to vibrations during a unidirectional movement.
The equipment was validated by manufacturing thin walls by deposition of a high strength low alloy (HSLA) steel wire with Gas Metal Arc Welding (GMAW), monitoring the thermal cycles by infrared thermography to evaluate them in different layers. Geometrical, microstructural and mechanical characterization of parts was performed.
Manufactured parts exhibited good surface finishing measured by the surface waviness that was around 300 μm and no internal defects were observed. Parts were isotropic as far as microstructural features and mechanical performance are concerned. The microstructure was mainly constituted by acicular ferrite and perlite with hardness below 320 HV. Energy dispersive spectrometry was performed, and no element loss was identified. Ultimate tensile strength varied between 700 and 809 MPa, depending on the process parameters. Resistance to impact was assessed by Charpy V impact tests with reduced size specimens and the absorbed energy registered was of 15 and 18 J, in longitudinal (Y) and normal (Z) directions, respectively. A ductile fracture surface was observed which is also a relevant indicator of mechanical performance of parts produced by WAAM in a HSLA steel.
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Duarte, Valdemar Rebelo. "Additive manufacturing of a high resistance steel by MIG/MAG." Master's thesis, 2016. http://hdl.handle.net/10362/19099.
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Additive manufacturing (AM) is considered to be part of the 4th Industrial Revolution in digital era with advances in product design, materials, process engineering and simulation and data transfer software. Recent developments focus in the production of metallic components with more complex shapes, big sizes at reduced costs. Special highlight has been given to welding technologies where the electric arc is the heat source and the consumable wire, the material to deposit. High deposition rate, relatively low costs and accessibility are the main reasons for the interest in wire and arc additive manufacturing (WAAM).
This study focused on using WAAM to produce simple shapes in high strength low alloy steel and characterize: the process, the geometrical features and the mechanical and structural properties of deposited material. The influence of the process parameters on the deposition characteristics was also studied.
It was concluded that arc welding is a feasible technology to produce components by WAAM in the material under study without internal defects. Both mechanical and structural characterization confirmed the integrity of produced parts. A constant material deposition was achieved, with a deposition width of about 5 mm and a waviness around 110 m, which is very much below reported results for other metallic materials. Tensile strength was above the one specified for the wire and is consistent with hardness measured, ranging from 800 MPa to 1 GPa depending on the heat input. Deposition rates from 122.9 to 427.5 cm3/h were obtained.
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Ó, Stefan Pereira do. "Wire and Arc Additive Manufacturing: Developments and Parts Characterization." Master's thesis, 2019. http://hdl.handle.net/10362/92301.
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Wire and arc additive manufacturing (WAAM) is a low capital investment technology that allows a reduction in material usage and production times while enabling the production of complex components. But despite its advantages, components produced in WAAM are prone to defects depending on the materials used and have overall inferior mechanical properties when compared to conventional processes.
This study focused on building and testing a system capable controlling the thermal cycles to manipulate the cooling rates and consequently the microstructure of produced parts in order to control the resulting hardness.
Two heat exchangers were built, one to heat and the other to cool the shielding gases. The exchangers were tested through the manufacturing of thin walls of 316L stainless steel and Inconel 625 superalloy using hot, ambient and cold argon gas. Obtained parts where characterized for their geometry, hardness and microstructure.
It was shown that varying the temperature of the shielding gas by itself is not enough to significantly influence the microstructure and mechanical properties of WAAM components. Using the cooling heat exchanger with cooling turned on caused an increase in hardness up to 30 HV and a decrease in primary dendrite arm spacing (PDAS) of 13.2 % for Inconel 625 while using the same heat exchanger without cooling caused an increase of 16.8 % in effective wall width (EWW) and a decrease of 15.8 % in height for 316L stainless steel. These differences were due to the cooling exchanger acting as a heat sink or as a heat accumulator depending on whether the cooling was turned on or off.
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Rodideal, Nicolae. "Mechanical characterization and fatigue assessment of wire and arc additive manufactured HSLA steel parts." Master's thesis, 2020. http://hdl.handle.net/10362/114034.
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Additive manufacturing is one of the main foundations of Industry 4.0. It aims,
particularly, to increase productivity, reducing material waste due to machining and bring
many advantages that overcome the conventional manufacturing processes. Wire and Arc
Additive Manufacturing (WAAM) is an additive manufacturing process that employs an
electric arc as heat source in order to melt and add material. It shows great versatility and
freedom to fabricate parts using a layer-by-layer method of deposition. Despite the clear
advantages presented, there still needs more progress in order to make it industrially
feasible. One of the main challenges it faces is studying the mechanical properties bet on
the desired geometry, type of material and the adopted parameters before employing these
components in critical operational loading conditions.
This dissertation aimed to assess the mechanical properties and fatigue resistance of
HSLA parts manufactured by this technology. In this way, two type of samples were
produced – one of low heat-input and another of high heat-input, in which the changing
variable was the travel speed. For each type, three thin walled parts were obtained,
measuring 180 x 100 mm each.
After manufacturing all the required samples, three different regions were analysed –
bottom, middle and top. Next, all parts were assiduously prepared in order to proceed
with material characterization as well as testing, specifically, waviness, microstructure,
electrical conductivity, microhardness, uniaxial tensile tests and lastly fatigue tests, with
subsequent fracture surface observation through Scanning Electron Microscope (SEM).
Fatigue tests were performed at room temperature on low heat-input samples with
constant stress amplitude, stress ratio R=0.1 and frequencies between 12 Hz and 15 Hz.
The S-N curve of the experimental results is presented along with an explanation within
the context of the other characterization techniques results.
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Bento, Emanuel Tavares. "ANÁLISE AO PROCESSO DE FABRICO POR WIRE-ARC ADDITIVE MANUFACTURING: Projeto e Realização de uma peça de comprovação de conceito." Master's thesis, 2021. http://hdl.handle.net/10316/98134.
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Dissertação de Mestrado Integrado em Engenharia Mecânica apresentada à Faculdade de Ciências e TecnologiaA 4ª Revolução Industrial, que decorre nos tempos atuais, pretende introduzir um conjunto de novas tecnologias no tecido industrial, entre elas, o fabrico aditivo. Este, por sua vez, promete revolucionar os processos produtivos atuais, uma vez que apresenta menores limitações em termos de complexidade geométrica, sendo possível adaptar a peça à respetiva função (em vez de a adaptar às limitações do método produtivo).Embora o foco inicial do fabrico aditivo tenha sido a implementação nos polímeros, em especial como método de ‘prototipagem rápida’, a classe de materiais com mais destaque na engenharia e indústria em geral é a dos metais, daí o recente interesse nas técnicas MAM, em especial as DED, que apresentam maiores taxas de deposição.No entanto, apesar das suas inúmeras vantagens, estas são técnicas ainda relativamente recentes, que carecem das décadas de conhecimento acumulado que os métodos convencionais possuem, pelo que, na sua maioria, ainda apresentam problemas a nível dimensional e das propriedades mecânicas obtidas, pelo que serão necessários mais estudos.Entre estas técnicas encontra-se o fabrico aditivo por arco elétrico (ou WAAM), a técnica em análise nesta dissertação. Assim, o objetivo deste trabalho é auxiliar no desenvolvimento desta tecnologia, nomeadamente, na análise inicial ao processo e no desenvolvimento duma metodologia que permita usar o sistema desenvolvido para obter peças a partir do respetivo modelo CAD.Esta dissertação é, portanto, composta por uma componente teórica onde é feita uma revisão sobre o fabrico aditivo em geral, a técnica WAAM, os sistemas cinemático e de controlo e a metodologia atualmente utilizada; e por uma componente prática onde é apresentado o sistema desenvolvido e, o procedimento experimental e respetivos resultados (ou seja, os problemas encontrados, soluções desenvolvidas e peças produzidas).
The 4th Industrial Revolution, which is taking place in current times, intends to introduce a set of new technologies into the manufacturing industry, one of them being 3D printing (or additive manufacturing). This, in turn, promises to revolutionize current production processes since it has fewer limitations in terms of geometric complexity, making it possible to adapt the part produced to its respective function (instead of adapting it to the limitations of the production method).Although its initial intent was to be implemented as a ‘rapid prototyping’ method to produce polymeric parts, the most prominent class of materials in engineering and industry in general are metals, hence the recent interest in MAM (metal additive manufacturing) techniques, in particular the ones classified under the DED (direct energy deposition) category, which have the highest deposition rates.However, despite their numerous advantages, these techniques are still relatively recent, lacking the decades of accumulated knowledge that conventional methods have. For that reason, they still present problems in terms of dimensional and mechanical properties, demonstrating the need for more studies to be performed.Among these techniques, wire-arc additive manufacturing (WAAM) is the method under analysis in this dissertation. Thus, the objective of this work is to assist in the development of this technology, namely, in the initial analysis of the process and in the development of a methodology that allows for the use of the system developed as a way to obtain parts from its CAD (computer-aided manufacturing) model.Therefore, this dissertation is composed of a theoretical part where a review is made about additive manufacturing in general, the WAAM technique, the kinematic and control systems and the methodology currently used, and by a practical part where the developed system and experimental procedure (problems found, solutions developed, and parts produced) are presented.
Book chapters on the topic "Additive Manufacturing, CAM, WAAM, Welding"
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Feucht, T., J. Lange, B. Waldschmitt, A. K. Schudlich, M. Klein, and M. Oechsner. "Welding Process for the Additive Manufacturing of Cantilevered Components with the WAAM." In Advanced Structured Materials, 67–78. Singapore: Springer Singapore, 2020. http://dx.doi.org/10.1007/978-981-15-2957-3_5.
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Manokruang, Supasit, Frederic Vignat, Matthieu Museau, and Maxime Limousin. "Process Parameters Effect on Weld Beads Geometry Deposited by Wire and Arc Additive Manufacturing (WAAM)." In Lecture Notes in Mechanical Engineering, 9–14. Cham: Springer International Publishing, 2021. http://dx.doi.org/10.1007/978-3-030-70566-4_3.
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AbstractAmong Additive Manufacturing technologies, Wire and Arc Additive Manufacturing process is strongly dependent of deposition conditions such as welding parameters, substrate temperature, trajectory. In this research, geometry and temperature evolutions of single beads have been investigated according to process parameters modifications. For our experiment, a heating device have been used in order to control the substrate temperature from room temperature up to 400 °C. Considering the Cold Metal Transfer technology, welding parameters, Wire Feed Speed (WFS) and Travel Speed (TS), have been modified while keeping a constant ratio λ (WFS/TS). Results indicate that weld bead geometry, height (h) and width (w), is influenced by substrate temperature and welding parameters. It has been shown that substrate temperature, itself influenced by process parameters, tends to produce thicker and lower weld beads while it increases.
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Chergui, Akram, Nicolas Beraud, Frédéric Vignat, and François Villeneuve. "Finite Element Modeling and Validation of Metal Deposition in Wire Arc Additive Manufacturing." In Lecture Notes in Mechanical Engineering, 61–66. Cham: Springer International Publishing, 2021. http://dx.doi.org/10.1007/978-3-030-70566-4_11.
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AbstractWire arc additive manufacturing allows the production of metallic parts by depositing beads of weld metal using arc-welding technologies. This low-cost additive manufacturing technology has the ability to manufacture large-scale parts at a high deposition rate. However, the quality of the obtained parts is greatly affected by the various thermal phenomena present during the manufacturing process. Numerical simulation remains an effective tool for studying such phenomena. In this work, a new finite element technique is proposed in order to model metal deposition in WAAM process. This technique allows to gradually construct the mesh representing the deposited regions along the deposition path. The heat source model proposed by Goldak is adapted and combined with the proposed metal deposition technique taking into account the energy distribution between filler material and the molten pool. The effectiveness of the proposed method is validated by series of experiments, of which an example is detailed in this paper.
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Klötzer, Christian, Martin-Christoph Wanner, Wilko Flügge, and Lars Greitsch. "Implementation of Innovative Manufacturing Technologies in Foundries for Large-Volume Components." In Annals of Scientific Society for Assembly, Handling and Industrial Robotics 2021, 229–40. Cham: Springer International Publishing, 2022. http://dx.doi.org/10.1007/978-3-030-74032-0_19.
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AbstractThe development of new manufacturing technologies opens up new perspectives for the production of propellers (diameter < 5 m), especially since the use of the established sand casting process as a technology is only partially competitive in today’s market. Therefore, different applications of generative manufacturing methods for the implementation into the production process were investigated. One approach is the mould production using additive manufacturing processes. Investigations showed that especially for large components with high wall thicknesses available systems and processes for sand casting mould production are cost-intensive and conditionally suitable. With our development of a large-format FDM printer, however, the direct production of large-format positive moulds for, for example, yacht propellers up to 4 m in diameter is possible. Due to the comparatively low accuracy requirements for the mould, the focus is on the durability of the drive system and the rigidity of this FDM printer. Equipped with simple linear technology in portal design and cubic design of the frame structure with rigid heated print bed, the aim is to achieve maximum material extrusion via the print head. The production of plastic models not only facilitates handling during the moulding process, but also allows considerable time and cost savings to be made during the running process. A further step in our development is the direct production of the components using WAAM. A possible concept for robot-supported build-up welding for the production of new innovative propeller geometries is presented using the example of a hollow turbine blade for a tidal power plant.
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Sowrirajan, Maruthasalam, Selvaraj Vijayan, and Munusamy Arulraj. "Welding Based Additive Manufacturing: Fundamentals." In Stainless Steels [Working Title]. IntechOpen, 2022. http://dx.doi.org/10.5772/intechopen.104768.
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Additive Manufacturing (AM) has drawn abundant attention over the past decades in the manufacturing and fabrication industries, especially to make part models and prototypes. This chapter introduces a potential welding based AM process called Wire Arc Additive Manufacturing (WAAM) for the fabrication of near-net shaped metal components including stainless steel components. To start with traditional AM processes, various fundamental traditional AM for the fabrication of components have been presented. Wire Arc Additive Manufacturing (WAAM) has been explained with its variants, synonyms, different welding processes to suit WAAM particularly to weld stainless steel metal; primary process selections for working with WAAM, important metals, and alloys that could be used in WAAM have been elaborated. A case study for WAAM fabrication of AISI 316 L stainless steel plate is included to introduce the fabrication of metal components using WAAM. Further, the most common defects which possibly play a vital role in WAAM components fabrication and a few of the future challenges regarding WAAM development are discussed. Fundamental information covered in this chapter could be more beneficial to beginners for the understanding of WAAM process generally including stainless steel component fabrication in a lucid tactic.
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Ramadan, Aya Abd Alla, Sherif Elatriby, Abd El Ghany, and Azza Fathalla Barakat. "Optimized Robotic WAAM." In Applications of Artificial Intelligence in Additive Manufacturing, 114–37. IGI Global, 2022. http://dx.doi.org/10.4018/978-1-7998-8516-0.ch006.
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This chapter summarizes a PhD thesis introducing a methodology for optimizing robotic MIG (metal inert gas) to perform WAAM (wire and arc additive manufacturing) without using machines equipped with CMT (cold metal transfer) technology. It tries to find the optimal MIG parameters to make WAAM using a welding robot feasible production technique capable of making functional products with proper mechanical properties. Some experiments were performed first to collect data. Then NN (neural network) models were created to simulate the MIG process. Then different optimization techniques were used to find the optimal parameters to be used for deposition. These results were practically tested, and the best one was selected to be used in the third stage. In the third stage, a block of metal was deposited. Then samples were cut from deposited blocks in two directions and tested for tension stress. These samples were successful. They showed behavior close to base alloy.
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Zinke, Manuela, Stefan Burger, and Sven Juettner. "Properties of Additively Manufactured Deposits of Alloy 718 Using CMT Process Depending on Wire Batch and Shielding Gas." In Welding Principles and Application [Working Title]. IntechOpen, 2022. http://dx.doi.org/10.5772/intechopen.102455.
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Wire + arc additive manufacturing (WAAM®) is a versatile, low-cost, energy-efficient technology used in metal additive manufacturing (AM). This process uses arc welding to melt a wire and form a three-dimensional (3D) object using a layer-by-layer deposit. In the present study, the effect of heat input and shielding gas during CMT-WAAM welding on cooling time, mechanical properties at room temperature, and macro- and microstructure was investigated based on different part geometries (wall, block) using two S Ni 7718 wire batches. The heat input and consequently the cooling rate were varied by changing the wire feed and the travel speed. As expected, increasing the heat input leads to higher cooling times. Due to the 2D-heat conduction, the thin walls cool significantly slower than the multi-pass block welds. Nevertheless, the influence on mechanical properties is only marginal. Both the AM batch of S Ni 7718 with the lower Nb/C and the multi-pass block welds with the higher thermomechanical reactions exhibit a high susceptibility to unacceptable seam defects, such as hot cracks or lacks of fusion. But even the standard batch causes hot cracks. An influence of the shielding gas on microstructure, mechanical properties, and occurrence of the seam defects cannot be detected.
Conference papers on the topic "Additive Manufacturing, CAM, WAAM, Welding"
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Zahid, Moosa, Khizar Hai, Mujtaba Khan, Ahmed Shekha, Salman Pervaiz, Syed Moneeb Ali, Omar Abdul-Latif, and Muhammad Salman. "Wire Arc Additive Manufacturing (WAAM): Reviewing Technology, Mechanical Properties, Applications and Challenges." In ASME 2020 International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers, 2020. http://dx.doi.org/10.1115/imece2020-23961.
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Abstract Because of the flexible nature of 3D printing and additive manufacturing technology, manufacturing sector has been revolutionized. There is a possibility to manufacture different intricate geometrics that cannot be produced through conventional processes previously. The conventional design concepts such as design for manufacture (DFM) and design for assembly (DFA) have been modified and simplified. Wire arc additive manufacturing (WAAM) has emerged as one of the leading additive manufacturing (AM) processes due to its high deposition rate and economic feasibility. A lot of progress has been made to understand and improve this process and the mechanical properties associated with the fabricated parts. It is specifically cheaper to print large-scale metallic components using WAAM. This paper gives a thorough review of the work that has been done on WAAM by comparing different technological variants of WAAM, which include Metal Inert Gas (MIG), Tungsten Inert Gas (TIG) and Plasma Arc Welding (PAW). The study also discusses the mechanical properties of the fabricated components using different metals, the defects and challenges the process faces today and how they can be reduced. In the end the study also provides overview of WAAM applications in some of the industrial sectors such as construction, automotive, and structural etc.
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Ruiz, Cesar, Davoud Jafari, Vignesh Venkata Subramanian, Tom H. J. Vaneker, Wei Ya, and Qiang Huang. "Improving Geometric Accuracy in Wire and Arc Additive Manufacturing With Engineering-Informed Machine Learning." In ASME 2022 17th International Manufacturing Science and Engineering Conference. American Society of Mechanical Engineers, 2022. http://dx.doi.org/10.1115/msec2022-85325.
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Abstract Wire and arc additive manufacturing (WAAM) is a promising technology for fast and cost-effective fabrication of large-scale components made of high-value materials for industries such as petroleum and aerospace. By using robotic arc welding and wire filler materials, WAAM can fabricate complex large near-net shape parts with high deposition rates, short lead times and millimeter resolution. However, due to high temperature gradients and residual stresses, current WAAM technologies suffer from high surface roughness and poor shape accuracy. This limits the adoption of these technologies in industry and complicates process control and optimization. Since its conception, considerable research efforts have been made on improving the mechanical and microstructural performance of WAAM components while few studies have investigated their geometric accuracy. In this work, we propose an engineering-informed machine learning (ML) framework for predicting and compensating for the geometric deformation of WAAM fabricated products based on a few sample parts. The proposed ML algorithm efficiently separates geometric shape deviation into deformation and surface roughness. Then, the predicted shape deformation of a new product is minimized by applying optimal geometric compensation to the product design. Experimental validation on cylindrical shapes showed that the proposed methodology can effectively reduce product shape deviation, which facilitates the widespread adoption of WAAM.
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Lange, Jörg, and Thilo Feucht. "3-D-Printing with Steel: Additive Manufacturing of Connection Elements and Beam Reinforcements." In IABSE Symposium, Guimarães 2019: Towards a Resilient Built Environment Risk and Asset Management. Zurich, Switzerland: International Association for Bridge and Structural Engineering (IABSE), 2019. http://dx.doi.org/10.2749/guimaraes.2019.1836.
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<p>Automated steel construction manufacturing with robots is no longer just a dream of the future but a reality. The Institute for Steel Structures and Materials Mechanics of the Technical University (TU) of Darmstadt/Germany has two welding robots. These robots are being used to assess various application for Additive Manufacturing. For the construction of steel, Wire + Arc Additive Manufacturing (WAAM) is suitable, which is similar to Gas-Shielded Metal Arc Welding. The wire electrode serves as printing material. With this method we can produce components in layers and achieve deposition rates of 5 kg/h. The components studied in this research project are connection elements such as simply supported girder connections and head plates and reinforcing elements such as stiffeners and beam reinforcements. In this paper topology-optimized structures are presented, which can be printed with the WAAM directly on steel beams.</p>
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Darnell, Mason, Dennis Harwig, and Xun Liu. "Experimental Analysis of Metal Inert Gas Based Wire Arc Additive Manufacturing of Aluminum Nanocomposite AA7075." In ASME 2022 17th International Manufacturing Science and Engineering Conference. American Society of Mechanical Engineers, 2022. http://dx.doi.org/10.1115/msec2022-85413.
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Abstract This work studies Metal Inert Gas (MIG) based Wire Arc Additive Manufacturing (WAAM) for nanoparticle enhanced AA7075. MIG WAAM is important for production and large structures due to its high deposition rates compared to Tungsten Inert Gas (TIG) or powder-based AM processes. Both MIG and TIG take advantage of wire feedstock, which is more readily available than powdered metals since the welding technology has been established for decades. Powder based processes allow for more complicated geometries but take significantly more time to produce and can suffer from voids which lead to non-uniform part density. TIG is normally used in welding of aluminum because it results in fewer defects, but the TiC/TiB2 nanoparticles eliminate solidification cracking normally associated with high strength aluminum alloys during welding. Porosity is another problem faced when welding aluminum, which can be affected by many things including deposition parameters, atmosphere and even the welding equipment used. Effects of different deposition parameters have been comprehensively studied including the deposition geometry and metallurgical properties. The process is also monitored with current/voltage measurement and high-speed imaging to understand the droplet transfer mode and molten pool development. The results are used to optimize process parameters to achieve the fewest defects possible while comparing different metal transfer modes. Multi-scale characterizations will be performed to examine the porosity distribution, solidification mode and grain size through optical microscopy. Future works will explore the distribution of secondary phases, precipitates, and nanoparticles through scanning electron microscopy (SEM) as well as conducting some mechanical testing of the as built structures such as hardness mapping and tensile tests.
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Hossain, Md Shahjahan, Hossein Taheri, Niraj Pudasaini, Alexander Reichenbach, and Bishal Silwal. "Ultrasonic Nondestructive Testing for In-Line Monitoring of Wire-Arc Additive Manufacturing (WAAM)." In ASME 2020 International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers, 2020. http://dx.doi.org/10.1115/imece2020-23317.
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Abstract The applications for metal additive manufacturing (AM) are expanding. Powder-bed, powder-fed, and wire-fed AM are the different kinds of AM technologies based on the feeding material. Wire-Arc AM (WAAM) is a wire-fed technique that has the potential to fabricate large-scale three-dimensional objects. In WAAM, a metallic wire is continuously fed to the deposition location and is melted by an arc-welding power source. As the applications for WAAM expands, the quality assurance of the parts becomes a major concern. Nondestructive testing (NDT) of AM parts is necessary for quality assurance and inspection of these materials. The conventional method of inspection is to perform testing on the finished parts. There are several limitations encountered when using conventional methods of NDT for as-built AM parts due to surface conditions and complex structure. In-situ process monitoring based on the ultrasound technology is proposed for WAAM material inspection during the manufacturing process. Ultrasonic inline monitoring techniques have the advantages of providing valuable information about the process and parts quality. Ultrasonic technique was used to detect the process condition deviations from the normal. A fixture developed by the authors holds an ultrasonic sensor under the build platform and aligned with the center of the base plate. Ultrasonic signals were measured for different process conditions by varying the current and gas flow rate. Features (indicators) from the radio frequency (RF) signal were used to evaluate the difference in signal clusters to identify and classify different build conditions. Results show that the indicator values of the ultrasonic signals in the region of interest (ROI) changes with different process conditions and can be used to classify them.
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Heinrich, Lauren, Thomas Feldhausen, Kyle S. Saleeby, Christopher Saldana, and Thomas R. Kurfess. "Prediction of Thermal Conditions of DED With FEA Metal Additive Simulation." In ASME 2021 16th International Manufacturing Science and Engineering Conference. American Society of Mechanical Engineers, 2021. http://dx.doi.org/10.1115/msec2021-63841.
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Abstract This paper presents the integration of wire-arc additive manufacturing (WAAM) using Gas Metal Arc Welding (GMAW) into a machine tool to create a retrofit hybrid computer numeric control (CNC) machine tool. GMAW, along with other direct energy deposition systems, has the capacity to deposit material faster than the excess thermal energy can dissipate. This results in the need to allow the part to cool between consecutive layers, which is the most time-consuming part of the additive process. Finite element analysis (FEA) was used in conjunction with monitored build plate surface temperatures during deposition samples to improve adequate dwell time prediction and to develop a cooling system. A deposition was completed where no dwell time was used and the build plate along with the machine table temperatures were monitored. A second deposition was completed where only one bead was deposited and the traverse speed was increased. The GMAW welder was mounted on a 3-axis CNC machine where two square deposition samples were completed. A FEA model was designed and verified using the monitored samples. The model will be used to determine improved depositions speeds and whether forced cooling would allow for an increased deposition rate without structural failure. It was determined the FEA software can be used to accurately model and predict the thermal response of WAAM AM components.
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Javadi, Yashar, Alistair Hutchison, Rastislav Zimermann, David Lines, Nina E. Sweeney, Momchil Vasilev, Ehsan Mohseni, et al. "Development of a Phased Array Ultrasonic System for Residual Stress Measurement in Welding and Additive Manufacturing." In ASME 2022 Pressure Vessels & Piping Conference. American Society of Mechanical Engineers, 2022. http://dx.doi.org/10.1115/pvp2022-85023.
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Abstract Residual Stress (RS) in engineering components can lead to unexpected and dangerous structural failures, and thus represent a significant challenge to quality assurance in both welding and metal additive manufacturing (AM) processes. The RS measurement using the ultrasonic method is based on the acoustoelasticity law, which states that the Time-of-Flight (ToF) of an ultrasonic wave is affected by the stress field. Longitudinal Critically Refracted (LCR) waves have the highest sensitivity to the stress in comparison with the other type of ultrasonic waves. However, they are also sensitive to the material texture which negatively affects the accuracy of the RS measurement. In this paper, a Phased Array Ultrasonic Testing (PAUT) system, rather than the single element transducers which are traditionally used in the LCR stress measurement technique, is innovatively used to enhance the accuracy of RS measurement. An experimental setup is developed that uses the PAUT to measure the ToFs in the weld, where the maximum amount of tensile RS is expected, and in the parent material, stress-free part. The ToF variations are then interpreted and analyzed to qualify the RS in the weld. The same measurement process is repeated for the Wire Arc Additive Manufacture (WAAM) components. Based on the results, some variations between different acoustic paths are measured which prove that the effect of the residual stress on the ultrasonic wave is detectable using the PAUT system.
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Abdallah, Said, and Salman Pervaiz. "Reviewing Post-Processing Techniques to Enhance Mechanical Properties of Parts Fabricated Using WAAM." In ASME 2021 International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers, 2021. http://dx.doi.org/10.1115/imece2021-73573.
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Abstract The different additive manufacturing (AM) technologies are showing a higher flexibility and process capabilities over the years, these technologies are not limited to produce a prototype only, but also to produce a valuable and cost-effective large near net parts. The Wire Arc Additive Manufacturing (WAAM) technique is regarded as one of the most important technologies for producing a metallic component. As it becomes one of the most interesting technology in the industrial sector, it can provide an unlimited printing size based on the used mechanism range. In this study, different microstructure deformation-based post processing methods have been discussed, some of them could be performed in-process (during) or even post-process (after) the WAAM technique. This study will focus more on the rolling deformation method comparing with the other post-processing techniques. Rolling process is observed as a good choice for post processing that can be used to improve the material microstructure features. Moreover, the parameters such as roller radius, applied load, the WAAM torch angle and the distance between the pressing side of the roller and the welding point show controlling influence on the internal grain features and on the surface waviness. surface roughness is termed as one of the main problems on the produce parts using WAAM technology. This study discussed different ways by which the internal residual stresses can be reduced, and mechanical properties of fabricated parts can be improved. Some studies revealed that hot forging can be used as a post processing technique after the WAAM process. Utilization of hot forging after the WAAM process shows an immediate positive effect on the produced sample by improving both of yield and ultimate strengths of the part. Furthermore, some other studies show that the forging significantly reduce the porosity due to the applied hot forging, as it is showing a higher effect with increasing the hammering force and vice versa. Also, some studies utilized rolling process as a post processing technique. So, the current study compared hot forging with the results extracted from the rolling deformation. This study aims to review the post processing techniques such as rolling process and hot forging process. The study provides understanding about the selection of the parameters to end up with a higher quality and tougher workpiece material. A comprehensive review on many rolling methods and directions during and after the WAAM process are discussed in detail. The main feature of this study is to provide a thorough understanding of the start-of-the-art involved in WAAM post processing. The study also revealed research gaps by comparing the existing literatures and adding a complete comparison and conclusions for each part which could be taken as potential in the future research topics for researchers in the same field. At the end, the manuscript has discussed the different post-processing design considerations that assure the best and the higher precision deposited part.
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Wang, Tingting, Yuanbin Zhang, Chuanwei Shi, Yueliang Xie, and Ke Wang. "Study on the Wire and Arc Additive Manufacturing Technology of Die Steel." In ASME 2018 13th International Manufacturing Science and Engineering Conference. American Society of Mechanical Engineers, 2018. http://dx.doi.org/10.1115/msec2018-6412.
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Wire and arc additive manufacturing (WAAM) technology has received increasing attention. In this paper, the thin-walled parts with the height of 230mm and cylindrical parts with the diameter of 100mm were fabricated by WAAM using H13 wire and Metal-Inert Gas Welding (MIG) method. Process parameters of current I = 140A, arc voltage U = 25V, velocity v = 4mm/s were applied to manufacture the thin-walled and cylindrical parts. During the WAAM process of the cylindrical parts, when the overlap length of a circle equal to the length of the puddle, the forming appearance of the part is reasonably good. By cooling the former layers with water, continuous processing of the parts was successfully realized. No obvious differences were detected when testing the hardness and the microstructure of the parts built by these two processes. The application of cooling may be a key technology for the continuous WAAM processing of the cylindrical specimens.
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O. Couto, Marcus, Ramon R. Costa, Antonio C. Leite, Fernando Lizarralde, Arthur G. Rodrigues, and João C. Payão Filho. "Weld Bead Width Measurement in a GMAW WAAM System by using Passive Vision." In Congresso Brasileiro de Automática - 2020. sbabra, 2020. http://dx.doi.org/10.48011/asba.v2i1.1121.
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The development and integration of Wire Arc Additive Manufacturing (WAAM) systems is nowadays a topic of growing interest. Industries are starting to focus on deploying this technology due to its vast capability of producing different types of parts and creating new possibilities for engineering design. Measuring the process characteristics is crucial in a WAAM system, because it helps to ensure that the build up was done according as planned. In this work, it was developed a passive vision-based monitoring method to measure the metal bead width in a WAAM process. The deposition was carried out by using a carbon steel wire with GMAW process, a Motoman HP20 robot arm and a welding torch device. A Xiris XVC-1000camera was used for visual inspection and mounted in a suitable configuration to minimize arc's noise. The experimental results show that it is possible to measure the bead deposition width in real time with a satisfactory accuracy using monocular cameras. Therefore, it is a feasible solution to be used in WAAM systems with the advantage of being relatively low-cost, as compared to other active vision equipment.