Journal articles: 'Wire Arc Additive Manufactoring'

1

Williams, S. W., F. Martina, A. C. Addison, J. Ding, G. Pardal, and P. Colegrove. "Wire + Arc Additive Manufacturing." Materials Science and Technology 32, no. 7 (February 9, 2016): 641–47. http://dx.doi.org/10.1179/1743284715y.0000000073.

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Casalino, Giuseppe, Mojtaba Karamimoghadam, and Nicola Contuzzi. "Metal Wire Additive Manufacturing: A Comparison between Arc Laser and Laser/Arc Heat Sources." Inventions 8, no. 2 (March 1, 2023): 52. http://dx.doi.org/10.3390/inventions8020052.

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In this paper, the authors introduce the reader to the state of the art of Metal Wire Additive Manufacturing (MWAM) and provide a comparison between Wire Arc Additive Manufacturing (WAAM), Wire Laser Additive Manufacturing (WLAM), and Laser Arc Hybrid Wire Deposition (LAHWD) based on their characteristics and potential future applications, since MWAM is expected to have a promising future in various areas, such as aerospace, automotive, biomedical, and energy fields. A detailed discussion of the benefits and drawbacks of each Metal Wire Additive Manufacturing process can help to improve our understanding of the unique characteristics of metal wire application. Therefore, this paper offers a comprehensive analysis that can serve as a reference for upcoming industrial projects and research initiatives, with the aim of helping industries choose the most appropriate WAM technique for their specific applications.

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Shukla, Pranjal, Balaram Dash, Degala Venkata Kiran, and Satish Bukkapatnam. "Arc Behavior in Wire Arc Additive Manufacturing Process." Procedia Manufacturing 48 (2020): 725–29. http://dx.doi.org/10.1016/j.promfg.2020.05.105.

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Lin, Zidong, Pengfei Liu, and Xinghua Yu. "A Literature Review on the Wire and Arc Additive Manufacturing—Welding Systems and Software." Science of Advanced Materials 13, no. 8 (August 1, 2021): 1391–400. http://dx.doi.org/10.1166/sam.2021.3971.

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Wire and arc additive manufacturing (WAAM) is considered to be an economic and efficient technology that is suitable to produce large-scale and ultra-large-scale metallic components. In the past two decades, it has been widely investigated in different fields, such as aerospace, automotive and marine industries. Due to its relatively high deposition rate, material efficiency, and shortened lead time compared to other powder-based additive manufacturing (AM) techniques, wire and arc additive manufacturing (WAAM) has been significantly noticed and adopted by both academic researchers and industrial engineers. In order to summarize the development achievements of wire and arc additive manufacturing (WAAM) in the past few years and outlook the development direction in the coming days, this paper provides an overview of 3D metallic printing by applying it as a deposition method. The review mainly focuses on the current welding systems, software for tool path design, generation, and planning used in wire and arc additive manufacturing (WAAM). In the end, the state of the art and future research on wire and arc additive manufacturing (WAAM) have been prospected.

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Derekar, K. S. "A review of wire arc additive manufacturing and advances in wire arc additive manufacturing of aluminium." Materials Science and Technology 34, no. 8 (April 8, 2018): 895–916. http://dx.doi.org/10.1080/02670836.2018.1455012.

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Kou, Fan, and Xiaoqiu Huang. "Current Research Situation and Prospect of Wire and Arc Additive Manufacturing of Titanium Alloy." Journal of Engineering System 2, no. 2 (June 2024): 39–46. http://dx.doi.org/10.62517/jes.202402207.

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Wire arc additive manufacturing is an important part of additive manufacturing. Because of its low processing cost, high forming efficiency, high material utilization rate and low equipment cost, it is favored in the fields of medical and aerospace. This paper briefly discuss the technologies of titanium alloy wire arc additive manufacturing. The influence of different deposited parameters, interpass rolling, ultrasonic assistance and heat treatment on the forming quality of titanium alloy wire arc additive components are summarized and analyzed. Finally, combined with the actual engineering requirements, the problems and research directions of the development of titanium alloy additive manufacturing are analyzed.

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Liu, Dan, Boyoung Lee, Aleksandr Babkin, and Yunlong Chang. "Research Progress of Arc Additive Manufacture Technology." Materials 14, no. 6 (March 15, 2021): 1415. http://dx.doi.org/10.3390/ma14061415.

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Additive manufacturing technology is a special processing technology that has developed rapidly in the past 30 years. The materials used are divided into powder and wire. Additive manufacturing technology using wire as the material has the advantages of high deposition rate, uniform composition, and high density. It has received increasingly more attention, especially for the high efficiency and rapid prototyping of large-size and complex-shaped components. Wire arc additive manufacturing has its unique advantages. The concept, connotation, and development history of arc additive manufacturing technology in foreign countries are reviewed, and the current research status of arc-based metal additive manufacturing technology is reviewed from the principles, development history, process, and practical application of arc additive manufacturing technology. It focuses on the forming system, forming material, residual stress and pores, and other defect controls of the technology, as well as the current methods of mechanical properties and process quality improvement, and the development prospects of arc additive manufacturing technology are prospected. The results show that the related research work of wire arc additive manufacturing technology is still mainly focused on the experimental research stage and has yet not gone deep into the exploration of the forming mechanism. The research work in this field should be more in-depth and systematic from the physical process of forming the molten pool system from the perspectives of stability, the organization evolution law, and performance optimization. We strive to carry out wire arc additive forming technology and theoretical research to promote the application of this technology in modern manufacturing.

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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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Guo, Chun, Maoxue Liu, Ruizhang Hu, Tuoyu Yang, Baoli Wei, Feng Chen, and Liyong Zhang. "High-strength wire + arc additive manufactured steel." International Journal of Materials Research 111, no. 4 (May 1, 2020): 325–31. http://dx.doi.org/10.1515/ijmr-2020-1110408.

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Abstract High-strength 690-MPa steel was prepared using a wire + arc additive manufacturing (WAAM) technology. The phase composition, microstructure, and crystal structure of highstrength 690-MPa steel samples were analysed, and the results show that a sample prepared using WAAM technology achieves a good formation quality. The metallographic structure was mainly acicular ferrite, massive ferrite, and granular bainite. The microhardness distribution of the vertical and horizontal sections of the samples is uniform. Excellent mechanical properties of the specimen were shown, including a horizontal yield strength of 536 MPa, a tensile strength of 760 MPa, an elongation of 23.5%, a Charpy impact value of 70 J at -508C, a vertical yield strength of 486 MPa, a tensile strength of 758 MPa, an elongation of 21.5%, and a Charpy impact value of 51 J at -508C.

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Klobcar, Damjan, Drago Bračun, Mirko Soković, Matija Bušić, S. Baloš, and Matej Pleterski. "Important findings in Wire + Arc Additive Manufacturing." Zavarivanje i zavarene konstrukcije 64, no. 3 (2019): 123–31. http://dx.doi.org/10.5937/zzk1903123k.

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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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Näsström, Jonas, Frank Brueckner, and Alexander F. H. Kaplan. "Laser enhancement of wire arc additive manufacturing." Journal of Laser Applications 31, no. 2 (May 2019): 022307. http://dx.doi.org/10.2351/1.5096111.

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Kulkarni, Sushrut M., and Sachin A. Mastud. "Development of Wire Arc Additive Manufacturing setup." International Journal of Innovations in Engineering and Science 6, no. 10 (August 19, 2021): 80. http://dx.doi.org/10.46335/ijies.2021.6.10.17.

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Guo, Chun, Maoxue Liu, Ruizhang Hu, Tuoyu Yang, Baoli Wei, Feng Chen, and Liyong Zhang. "High-strength wire + arc additive manufactured steel." International Journal of Materials Research 111, no. 4 (April 15, 2020): 325–31. http://dx.doi.org/10.3139/146.111890.

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Petrov, Krum, and Evgeny Tongov. "MECHANICAL SYSTEM FOR WIRE ARC ADDITIVE MANUFACTURING." ENVIRONMENT. TECHNOLOGIES. RESOURCES. Proceedings of the International Scientific and Practical Conference 1 (June 13, 2023): 171–74. http://dx.doi.org/10.17770/etr2023vol1.7282.

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This article discusses the reassembly of a mechanical system for 3D printing plastic parts to be used for plasma arc additive manufacturing. The main issues in converting an existing 3D printer designed for plastic additive to used for producing metal parts are: control of the welding power source; installation and realization of the movement with the welding torch; set the height of the zero layer; setting up the program software to generate the control file.

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Köhler, Markus, Sierk Fiebig, Jonas Hensel, and Klaus Dilger. "Wire and Arc Additive Manufacturing of Aluminum Components." Metals 9, no. 5 (May 24, 2019): 608. http://dx.doi.org/10.3390/met9050608.

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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.

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Ayed, A., G. Bras, H. Bernard, P. Michaud, Y. Balcaen, and J. Alexis. "Study of Arc-wire and Laser-wire processes for the realization of Ti-6Al-4V alloy parts." MATEC Web of Conferences 321 (2020): 03002. http://dx.doi.org/10.1051/matecconf/202032103002.

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Arc-wire or laser-wire additive manufacturing seems promising because it allows large parts to be produced with significant deposition rates (ten times higher than powder bed additive manufacturing), for a lower investment cost. These additive manufacturing techniques are also very interesting for the construction or the repair of parts. A versatile 3D printing device using a Wire Arc Additive Manufacturing (WAAM) station or laser device Wire Laser Additive Manufacturing (WLAM) for melting a filler wire is developed to repair and build large titanium parts. The final objectives of the study are to optimize the process parameters to control the dimensional stability, the metallurgical and mechanical properties of the produced parts. In this paper, an experimental study is carried out to determine the first order process parameter ranges (synergic law, laser power, wire feed speed, travel speed) appropriate for these two techniques, for repair or construction parts on Ti-6 Al-4V.

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Prabhakaran, B., P. Sivaraj, S. Malarvizhi, V. Balasubramanian, and S. Sathiya. "Metal Cored Wire on Mechanical Properties and Microstructural Characteristics of Wire Arc Direct Energy Deposited Component." Indian Journal Of Science And Technology 17, no. 44 (December 10, 2024): 4655–62. https://doi.org/10.17485/ijst/v17i44.3514.

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Objectives: Fabrication of a cylinder-shaped High-Strength Low Alloyed steel wall component through wire (metal cored) arc additive manufacturing and assess the homogeneity and integrity of the built component. Method: Mechanical testing and microstructural characterizations such as optical microscopy, scanning electron microscopy and electron backscattered diffraction techniques were performed at distinct regions (namely, bottom and top). Findings: The conducted tensile test at the bottom area recorded a tensile strength of 864 MPa, which is 5.9 % higher than the top region but with a lower total elongation. The microhardness study revealed that the average hardness at the bottom region was 266 HV0.5, while the top region was 241 HV0.5. The microstructural analysis conducted in both areas indicates that the bottom region exhibits better hardness and strength due to the presence of a high value of geometrically necessary dislocations, High-Angle Grain Boundaries and increased grains with reduced size. However, the built component proves to have better homogeneity with marginal deviations in the properties estimated. Novelty: Solid wire was used as a predominant filler material for the Wire-Arc Additive Manufacturing (WAAM) process, which requires high heat input to melt the material. Hence, to reduce the heat input, metal-cored wire was used instead of solid wire for the Gas Metal Arc -WAAM process. Keywords: Gas metal arc welding, Metal cored wire, Mechanical properties, Direct energy deposition, Wire-arc additive manufacturing

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Singh, Shalini, Arackal Narayanan Jinoop, Gorlea Thrinadh Ananthvenkata Tarun Kumar, Iyamperumal Anand Palani, Christ Prakash Paul, and Konda Gokuldoss Prashanth. "Effect of Interlayer Delay on the Microstructure and Mechanical Properties of Wire Arc Additive Manufactured Wall Structures." Materials 14, no. 15 (July 27, 2021): 4187. http://dx.doi.org/10.3390/ma14154187.

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Wire arc additive manufacturing is a metal additive manufacturing technique that allows the fabrication of large size components at a high deposition rate. During wire arc additive manufacturing, multi-layer deposition results in heat accumulation, which raises the preheat temperature of the previously built layer. This causes process instabilities, resulting in deviations from the desired dimensions and variations in material properties. In the present study, a systematic investigation is carried out by varying the interlayer delay from 20 to 80 s during wire arc additive manufacturing deposition of the wall structure. The effect of the interlayer delay on the density, geometry, microstructure and mechanical properties is investigated. An improvement in density, reduction in wall width and wall height and grain refinement are observed with an increase in the interlayer delay. The grain refinement results in an improvement in the micro-hardness and compression strength of the wall structure. In order to understand the effect of interlayer delay on the temperature distribution, numerical simulation is carried out and it is observed that the preheat temperature reduced with an increase in interlayer delay resulting in variation in geometry, microstructure and mechanical properties. The study paves the direction for tailoring the properties of wire arc additive manufacturing-built wall structures by controlling the interlayer delay period.

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Peyre, Patrice. "Additive Layer Manufacturing using Metal Deposition." Metals 10, no. 4 (April 1, 2020): 459. http://dx.doi.org/10.3390/met10040459.

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Among the additive layer manufacturing techniques for metals, those involving metal deposition, including laser cladding/Direct Energy Deposition (DED, with powder feeding) or Wire and Arc Additive Manufacturing (WAAM, with wire feeding), exhibit several attractive features [...]

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Zeng, Jiayi, Wenzhong Nie, and Xiaoxuan Li. "The Influence of Heat Input on the Surface Quality of Wire and Arc Additive Manufacturing." Applied Sciences 11, no. 21 (October 30, 2021): 10201. http://dx.doi.org/10.3390/app112110201.

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Wire and arc additive manufacturing has unique process characteristics, which make it have great potential in many fields, but the large amount of heat input brought by this feature limits its practical application. The influence of heat input on the performance of parts has been extensively studied, but the quantitative description of the influence of heat input on the surface quality of parts by wire and arc additive manufacturing has not received enough attention. According to different heat input, select the appropriate process parameters for wire and arc additive manufacturing, reversely shape the profile model, select the appropriate function model to establish the ideal profile model according to the principle of minimum error, and compare the two models to analyze the effect of heat input on the surface quality of the parts manufactured by wire and arc additive manufacturing. The results show that, when the heat input is high or low, the standard deviation value and the root mean square value reach 1.908 and 1.963, respectively. The actual profile is larger than the ideal profile. When the heat input is moderate, the standard deviation value and the root mean square value are only 1.634 and 1.713, respectively, and the actual contour is in good agreement with the ideal contour. Combined with the analysis of the transverse and longitudinal sections, it is shown that the heat input has a high degree of influence on the surface quality of the specimen manufactured by wire and arc additive manufacturing, and higher or lower heat input is disadvantageous to it.

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V, Vinoth, Sathiyamurthy S, Prabhakaran J, Harsh Vardhan, Sundaravignesh S, and Sanjeevi Prakash K. "Tensile, Hardness, XRD and Surface Vonmises Stress of 316 L Stainless Steel Built by Wire Arc Additive Manufacturing (WAAM)." Journal of Manufacturing Engineering 17, no. 3 (September 1, 2022): 098–103. http://dx.doi.org/10.37255/jme.v17i3pp098-103.

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Wire arc additive manufacturing (WAAM) is a popular wire feed additive manufacturing technology that creates components through the deposition of material layer-by-layer. WAAM has become a promising alternative to conventional machining due to its high deposition rate, environmental friendliness, and cost-competitiveness. It is used to Fabricate complex shaped parts. The variable parameters are current, welding speed, shielding gas, and gas flow rate. This research fabricates 316 L stainless steel (WAAM plate) using a wire arc welding robot machine. Substrate and Side edges are removed using Microwire cut EDM, and the vertical milling machine finishes the surface. The tensile, hardness and X-ray Diffraction are compared with the standard 316 L stainless steel. The modelling and analysis of 316L stainless steel are carried out using COMSOL Multiphysics 5.3 software. It is concluded that the additive manufacturing of 316L stainless steel by wire and arc process is feasible.

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Bento, João B., Chong Wang, Jialuo Ding, and Stewart Williams. "Process Control Methods in Cold Wire Gas Metal Arc Additive Manufacturing." Metals 13, no. 8 (July 26, 2023): 1334. http://dx.doi.org/10.3390/met13081334.

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Cold wire gas metal arc (CWGMA) additive manufacturing (AM) is more productive and beneficial than the common electric arc processes currently used in wire arc additive manufacturing (WAAM). Adding a non-energised wire to the gas metal arc (GMA) system makes it possible to overcome a process limitation and decouple the energy input from the material feed rate. Two novel process control methods were proposed, namely, arc power and travel speed control, which can keep the required geometry accuracy in WAAM through a broad range of thermal conditions. The reinforcement area of the bead is kept constant with accurate control over the height and width while still reducing the energy input to the substrate; decreasing penetration depth, remelting, and the heat-affected zone (HAZ); and reaching a dilution lower than 10%. This work also presents improved productivity compared to all the other single-arc energy-based processes with a demonstrator part built using 9.57 kg h−1 with CWGMA AM.

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Singh, Harpuneet, Bikramjit Singh, and Gurcharan Singh. "Current Trends in Wire Arc Additive Manufacturing- A Review." International Journal of Advance Research and Innovation 10, no. 3 (2022): 74–80. http://dx.doi.org/10.51976/ijari.1032210.

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Wire arc additive manufacturing (WAAM) is a fusion manufacturing process in which the heat energy of an electric arc is employed for melting the electrodes and depositing material layers for wall formation or for simultaneously cladding two materials in order to form a composite structure. This directed energy deposition-arc (DED-arc) method is advantageous and efficient as it produces large parts with structural integrity due to the high deposition rates, reduced wastage of raw material, and low consumption of energy in comparison with the conventional joining processes and other additive manufacturing technologies. These features have resulted in a constant and continuous increase in interest in this modern manufacturing technique which demands further studies to promote new industrial applications.

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Souto, Joyce Ingrid Venceslau de, Jefferson Segundo de Lima, Walman Benício de Castro, Renato Alexandre Costa de Santana, Antonio Almeida Silva, Tiago Felipe de Abreu Santos, and João Manuel R. S. Tavares. "Effects of Contaminations on Electric Arc Behavior and Occurrence of Defects in Wire Arc Additive Manufacturing of 316L Stainless Steel." Metals 14, no. 3 (February 29, 2024): 286. http://dx.doi.org/10.3390/met14030286.

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Additive Manufacturing is a manufacturing process that consists of obtaining a three-dimensional object from the deposition of material layer by layer, unlike conventional subtractive manufacturing methods. Wire Arc Additive Manufacturing stands out for its high productivity among the Additive Manufacturing technologies for manufacturing metal parts. On the other hand, the excessive heat input promotes increased residual stress levels and the occurrence of defects, such as pores, voids, a lack of fusion, and delamination. These defects result in abnormalities during the process, such as disturbances in electrical responses. Therefore, process monitoring and the detection of defects and failures in manufactured items are of fundamental importance to ensure product quality and certify the high productivity characteristic of this process. Thus, this work aimed to characterize the effects of different contaminations on the electric arc behavior of the Wire Arc Additive Manufacturing process and the occurrence of microscopic defects in thin walls manufactured by this process. To investigate the presence of defects in the metal preforms, experimental conditions were used to promote the appearance of defects, such as the insertion of contaminants. To accomplish the electric arc behavior analysis, voltage and current temporal data were represented through histograms and cyclograms, and the arc stability was assessed based on the Vilarinho index for a short circuit. Effectively, the introduction of contaminants caused electric arc disturbances that led to the appearance of manufacturing defects, such as inclusions and porosities, observed through metallographic characterization. The results confirm that the introduction of contaminations could be identified early in the Wire Arc Additive Manufacturing process through electric arc data analysis.

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Abbaszadeh, Masoud, Volker Ventzke, Leonor Neto, Stefan Riekehr, Filomeno Martina, Nikolai Kashaev, Jan Hönnige, Stewart Williams, and Benjamin Klusemann. "Compression Behaviour of Wire + Arc Additive Manufactured Structures." Metals 11, no. 6 (May 27, 2021): 877. http://dx.doi.org/10.3390/met11060877.

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Increasing demand for producing large-scale metal components via additive manufacturing requires relatively high building rate processes, such as wire + arc additive manufacturing (WAAM). For the industrial implementation of this technology, a throughout understanding of material behaviour is needed. In the present work, structures of Ti-6Al-4V, AA2319 and S355JR steel fabricated by means of WAAM were investigated and compared with respect to their mechanical and microstructural properties, in particular under compression loading. The microstructure of WAAM specimens is assessed by scanning electron microscopy, electron back-scatter diffraction, and optical microscopy. In Ti-6Al-4V, the results show that the presence of the basal and prismatic crystal planes in normal direction lead to an anisotropic behaviour under compression. Although AA2319 shows initially an isotropic plastic behaviour, the directional porosity distribution leads to an anisotropic behaviour at final stages of the compression tests before failure. In S355JR steel, isotropic mechanical behaviour is observed due to the presence of a relatively homogeneous microstructure. Microhardness is related to grain morphology variations, where higher hardness near the inter-layer grain boundaries for Ti-6Al-4V and AA2319 as well as within the refined regions in S355JR steel is observed. In summary, this study analyzes and compares the behaviour of three different materials fabricated by WAAM under compression loading, an important loading condition in mechanical post-processing techniques of WAAM structures, such as rolling. In this regard, the data can also be utilized for future modelling activities in this direction.

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Rodrigues, Tiago A., Valdemar R. Duarte, R. M. Miranda, Telmo G. Santos, and J. P. Oliveira. "Ultracold-Wire and arc additive manufacturing (UC-WAAM)." Journal of Materials Processing Technology 296 (October 2021): 117196. http://dx.doi.org/10.1016/j.jmatprotec.2021.117196.

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ABE, Takeyuki, and Hiroyuki SASAHARA. "Study on Wire and Arc-based Additive Manufacturing." JOURNAL OF THE JAPAN WELDING SOCIETY 86, no. 7 (2017): 500–504. http://dx.doi.org/10.2207/jjws.86.500.

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Chernovol, Nataliia, Abhay Sharma, Tegoeh Tjahjowidodo, Bert Lauwers, and Patrick Van Rymenant. "Machinability of wire and arc additive manufactured components." CIRP Journal of Manufacturing Science and Technology 35 (November 2021): 379–89. http://dx.doi.org/10.1016/j.cirpj.2021.06.022.

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Zou, Lei, Lei Li, Jian Hua Cai, Hai Ying Yang, and Jun Chen. "Forming Process of Wire and Arc Additive Manufacture." Materials Science Forum 1035 (June 22, 2021): 198–205. http://dx.doi.org/10.4028/www.scientific.net/msf.1035.198.

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The forming process of wire and arc additively manufacture (WAAM) was studied using the self-developed and designed WAAM system. The single-pass and single-layer weld bead samples were prepared with different process parameters, and the cross-sectional dimensions of the weld bead were measured. The influence rules of weld current, welding speed, wire feed speed and welding height on the weld bead size were obtained. In addition, the overlap experiment of the WAAM forming process was also carried out. The multiple and multilayer lap samples with different overlap rates were prepared, and the cross-sections of the lap samples were observed and analyzed. Finally, the overlap rate range of 35-45% with good forming effect was obtained.

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Oliveira, J. P., Francisco M. Gouveia, and Telmo G. Santos. "Micro wire and arc additive manufacturing (µ-WAAM)." Additive Manufacturing Letters 2 (April 2022): 100032. http://dx.doi.org/10.1016/j.addlet.2022.100032.

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Dhinakaran, V., B. Stalin, M. Ravichandran, M. Balasubramanian, C. Anand Chairman, and D. Pritima. "Wire Arc Additive Manufacturing Perspectives and Recent Developments." IOP Conference Series: Materials Science and Engineering 988 (December 16, 2020): 012102. http://dx.doi.org/10.1088/1757-899x/988/1/012102.

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Mehnen, Jörn, Jialuo Ding, Helen Lockett, and Panos Kazanas. "Design study for wire and arc additive manufacture." International Journal of Product Development 19, no. 1/2/3 (2014): 2. http://dx.doi.org/10.1504/ijpd.2014.060028.

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Kokare, Samruddha, João P. Oliveira, and Radu Godina. "Modelling of Wire Arc Additive Manufactured Product Cost." Procedia Computer Science 217 (2023): 1513–21. http://dx.doi.org/10.1016/j.procs.2022.12.351.

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Ríos, Sergio, Paul A. Colegrove, Filomeno Martina, and Stewart W. Williams. "Analytical process model for wire + arc additive manufacturing." Additive Manufacturing 21 (May 2018): 651–57. http://dx.doi.org/10.1016/j.addma.2018.04.003.

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Arana, Maider, Eneko Ukar, David Aguilar, and Pedro Álvarez. "Wire arc additive manufacturing of nanomodified 2024 alloy." Materials Letters 348 (October 2023): 134712. http://dx.doi.org/10.1016/j.matlet.2023.134712.

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Tongov, Manahil, and Vladimir Petkov. "A THERMAL MODEL FOR WIRE ARC ADDITIVE MANUFACTURING." ENVIRONMENT. TECHNOLOGIES. RESOURCES. Proceedings of the International Scientific and Practical Conference 3 (June 13, 2023): 262–70. http://dx.doi.org/10.17770/etr2023vol3.7212.

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Layer-by-layer detailing processes, which used wire and electric arc - wire arc additive manufacturing (WAAM), are among the most productive in 3D metal printing technologies. From this point of view, the solution of the thermal task, and subsequently of the deformation problem, are particularly relevant. It is natural that these simulation modelling processes are closely related to welding, but at the same time it is necessary to take into account particularities that are crucial for WAAM and are not always relevant in welding. In this research, one such model is proposed, which takes into account the gradual filling of the working space with the deposited metal. The specific issues related to the construction of the model, the definition of the heat source and the first layer formation in the conditions of WAAM are considered. The obtained numerical results enable the prediction of the layer dimensions.

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Sampaio, R. F. V., J. P. M. Pragana, I. M. F. Bragança, C. M. A. Silva, C. V. Nielsen, and P. A. F. Martins. "Modelling of wire-arc additive manufacturing – A review." Advances in Industrial and Manufacturing Engineering 6 (May 2023): 100121. http://dx.doi.org/10.1016/j.aime.2023.100121.

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Bettine, Farid, Ammar Haboussi, Fayçal Bouzid, and Boussaha Bouchoul. "Toolpath generation strategy of wire arc additive manufacturing." Brazilian Applied Science Review 9, no. 1 (January 10, 2025): e76687. https://doi.org/10.34115/basrv9n1-002.

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Wire-Arc Additive Manufacturing (WAAM) is a promising technology in the field of metal additive manufacturing, enabling the production of large-scale, complex metal components. A critical aspect of WAAM is the generation of efficient and accurate tool-paths, which directly influence the quality, structural integrity, and material properties of the fabricated parts. This paper presents a novel strategy for generating optimized tool-paths in WAAM, focusing on enhancing deposition efficiency while minimizing material waste and thermal distortions. The proposed approach integrates advanced computational algorithms with real-time process feedback to adaptively adjust the tool-paths based on in-situ conditions. Simulation and experimental results demonstrate the effectiveness of this strategy in improving build quality, reducing defects, and achieving consistent material deposition. The developed methodology offers a significant step forward in the automation and precision of WAAM, paving the way for its broader industrial adoption.

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40

Feng, Yi, and Ding Fan. "Investigating the Forming Characteristics of 316 Stainless Steel Fabricated through Cold Metal Transfer (CMT) Wire and Arc Additive Manufacturing." Materials 17, no. 10 (May 7, 2024): 2184. http://dx.doi.org/10.3390/ma17102184.

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Wire and arc additive manufacturing (WAAM), recognized for its capability to fabricate large-scale, complex parts, stands out due to its significant deposition rates and cost-effectiveness, positioning it as a forward-looking manufacturing method. In this research, we employed two welding currents to produce samples of 316 austenitic stainless steel utilizing the Cold Metal Transfer wire arc additive manufacturing process (CMT-WAAM). This study initially evaluated the maximum allowable arc travel speed (MAWFS) and the formation characteristics of the deposition bead, considering deposition currents that vary between 100 A and175 A in both CMT and CMT pulse(CMT+P) modes. Thereafter, the effect of the CMT+P mode arc on the microstructure evolution was analyzed using the EBSD technique. The findings indicate that the arc travel speed and deposition current significantly affect the deposition bead’s dimensions. Specifically, an increase in travel speed or a reduction in current results in reduced bead width and height. Moreover, the employment of the CMT+P arc mode led to a reduction in the average grain size in the mid-section of the sample fabricated by CMT arc and wire additive manufacturing, from 13.426 μm to 9.429 μm. Therefore, the components of 316 stainless steel produced through the CMT+P-WAAM method are considered fit for industrial applications.

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Song, Xueping, Zhuoxuan Li, Jiankang Huang, Ding Fan, and Shurong Yu. "Analysis of Droplet Transfer and Arc Swing in “TIG + AC” Twin-Wire Cross Arc Additive Manufacturing." Metals 13, no. 1 (December 26, 2022): 63. http://dx.doi.org/10.3390/met13010063.

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Twin-wire and arc additive manufacturing (T-WAAM) has potential advantages in improving deposition efficiency and manufacturing functionally graded materials (FGMs), thus attracting much attention. However, there are few studies on the droplet transfer mode of T-WAAM. This paper analyzes the droplet transfer mode and arc swing in the “TIG + AC” twin-wire cross-arc additive manufacturing by in-situ observation with high-speed photography, revealing what factors influence the T-WAAM on deposition shaping the quality and what are the key mechanisms for process stability. Experiments show that with the main arc current provided by TIG 100 A and the twin-wire AC arc current 10 A, three different droplet transfer modes, namely the “free transfer + free transfer, bridge transfer + free transfer, bridge transfer + bridge transfer,” can be observed with the twin wires under different feeding speeds. The corresponding deposition and arc swing are quite different in quality. Through comparative analysis, it is found that the frequent extinguishment and ignition of the arc between electrode wires is the main factor for the instability in the additive manufacturing process. The “bridge transfer + free transfer” mode can obtain a large arc swing angle and a stable deposition, in which the cross arc has a significant stirring effect on the molten pool, and the deposition shape is well-made.

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Klobčar, Damjan, Sebastijan Baloš, Matija Bašić, Aleksija Djurić, Maja Lindič, and Aljaž Ščetinec. "WAAM and Other Unconventional Metal Additive Manufacturing Technologies." Advanced Technologies & Materials 45, no. 2 (December 15, 2020): 1–9. http://dx.doi.org/10.24867/atm-2020-2-001.

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The paper presents an overview of metal additive manufacturing technologies. The emphasis is on unconventional emerging technologies with firm background on welding technologies such as Ultrasonic Additive Manufacturing, Friction Additive Manufacturing, Thermal Spray Additive Manufacturing, Resistance Additive Manufacturing and Wire and Arc Additive Manufacturing. The particular processes are explained in detail and their advantages and drawbacks are presented. Attention is made on materials used, possibilities to produce multi-material products and functionally graded materials, and typical applications of currently developed technologies. The state-of-the-art on the Wire and Arc Additive Manufacturing is presented in more detail due to high research interests, it’s potential and widespread. The main differences between different arc additive manufacturing technologies are shown. An influence of processing parameters is discussed with respect to process stability and process control. The challenges related to path planning are shown together with the importance of post-processing. The main advantage of presented technologies is their ability of making larger and multi-material parts, with high deposition rate, which is difficult to achieve using conventional additive technologies.

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B T, Anirudhan, Jithin Devasia, Tejaswin Krishna, and Mebin T. Kuruvila. "Manufacturing of a Bimetallic Structure of Stainless Steel and Mild Steel through Wire Arc Additive Manufacturing – A Critical Review." International Journal of Innovative Science and Research Technology 5, no. 6 (July 3, 2020): 679–85. http://dx.doi.org/10.38124/ijisrt20jun583.

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Wire and Arc based Additive Manufacturing, shortly known as WAAM, is one of the most prominent tech- nologies, under Additive Manufacturing, used for extensive production of complex and intricate shapes. This layer by layer deposition method avails arc welding technology; Gas Metal Arc Welding (GMAW), a competitive method in WAAM, is the conducted manufacturing process. It is a sum of heat source, originated from the electric arc, and metal wire as feedstock. The metal wire from the feedstock, melted by arc discharge, is deposited layer by layer. Another material can be added on to the top of deposited layer by replacing the feed wire from the stock, to fabricate a bimetallic structure. The purpose of this study is to collect the salient datum from the joining of two dissimilar metals. A combination of stainless steel and mild steel are considered. Proper deposition parameters, welding current along with voltage, bead width efficiency for both the metals were acquired. As a result, the physical properties of the dissimilar joint were approximate to the bulk material.

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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.

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Voropaev, Artem, Rudolf Korsmik, and Igor Tsibulskiy. "Features of Filler Wire Melting and Transferring in Wire-Arc Additive Manufacturing of Metal Workpieces." Materials 14, no. 17 (September 5, 2021): 5077. http://dx.doi.org/10.3390/ma14175077.

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In this paper, we present the results of a study on droplet transferring with arc space short circuits during wire-arc additive manufacturing (WAAM GMAW). Experiments were conducted on cladding of single beads with variable welding current and voltage parameters. The obtained oscillograms and video recordings were analyzed in order to compare the time parameters of short circuit and arc burning, the average process peak current, as well as the droplets size. Following the experiments conducted, 2.5D objects were built-up to determine the influence of electrode stickout and welding torch travel speed to identify the droplet transferring and formation features. Moreover, the current–voltage characteristics of the arc were investigated with varying WAAM parameters. Process parameters have been determined that make it possible to increase the stability of the formation of the built-up walls, without the use of specialized equipment for forced droplet transfer. In the course of the research, the following conclusions were established: the most stable drop transfer occurs at an arc length of 1.1–1.2 mm, reverse polarity provides the best drop formation result, the stickout of the electrode wire affects the drop transfer process and the quality of the deposited layers. The dependence of the formation of beads on the number of short circuits per unit length is noted.

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Solanke, Narendra, and Rajesh M. Metkar. "Optimization of welding process parameters of wire arc additive manufacturing." Journal of Physics: Conference Series 2763, no. 1 (May 1, 2024): 012018. http://dx.doi.org/10.1088/1742-6596/2763/1/012018.

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Abstract Wire arc additive manufacturing (WAAM) is a cost-effective and efficient method for producing intricate metal geometries. This study employs Design Expert software and the desirability function to optimize WAAM process parameters, focusing on maximizing bead width, height, and microhardness—critical factors determining mechanical properties. Through ANOVA analysis, the research identifies voltage, wire feed speed, and torch speed as significantly influencing welding characteristics. Increased voltage and wire feed speed yield wider beads, while higher torch and wire feed speeds enhance bead height and microhardness. Optimized parameters—16.44 V voltage, 8.99 m/min wire feed speed, and 9 mm/s torch speed—demonstrate precise control over bead properties. This study deepens our understanding of WAAM process parameters, offering valuable insights for consistently producing high-quality weld beads with desired mechanical properties. The findings have profound implications for the manufacturing industry, enabling enhanced efficiency, consistency, and quality in metal component production. Optimized parameters also pave the way for innovative designs, lightweight structures, and rapid prototyping, contributing to the advancement of additive manufacturing, particularly in the context of wire arc technology. This research establishes a foundation for future studies on process optimization, material selection, and widespread WAAM adoption in diverse manufacturing sectors.

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Treutler, Kai, Swenja Lorenz, Jens Hamje, and Volker Wesling. "Wire and Arc Additive Manufacturing of a CoCrFeMoNiV Complex Concentrated Alloy Using Metal-Cored Wire—Process, Properties, and Wear Resistance." Applied Sciences 12, no. 13 (June 21, 2022): 6308. http://dx.doi.org/10.3390/app12136308.

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The field of complex concentrated alloys offers a very large number of variations in alloy composition. The achievable range of properties varies greatly within these variants. The experimental determination of the properties is in many cases laborious. In this work, the possibility of using metal-cored wires to produce sufficient large samples for the determination of the properties using arc-based additive manufacturing or in detail wire and arc additive manufacturing (WAAM) is to be demonstrated by giving an example. In the example, a cored wire is used for the production of a CoCrFeNiMo alloy. In addition to the process parameters used for the additive manufacturing, the mechanical properties of the alloy produced in this way are presented and related to the properties of a cast sample with a similar chemical composition. The characterization of the resulting microstructure and wear resistance will complete this work. It will be shown that it is possible to create additively manufactured structures for a microstructure and a property determination by using metal-cored filler wires in arc-based additive manufacturing. In this case, the additively manufactured structure shows an FCC two-phased microstructure, a yield strength of 534 MPa, and a decent wear resistance.

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Hu, Qingxian, Xiaoli Wang, Xinwang Shen, and Zemin Tan. "Microstructure and Corrosion Resistance in Bimetal Materials of Q345 and 308 Steel Wire-Arc Additive Manufacturing." Crystals 11, no. 11 (November 17, 2021): 1401. http://dx.doi.org/10.3390/cryst11111401.

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The microstructure and corrosion resistance of samples fabricated by Q345 and 308 bimetallic feedings using two kinds of processes of wire-arc additive manufacturing (WAAM) was observed and compared with that of sample manufactured by a single feeding wire of Q345 or 308. The results show that the interface between the Q345 and 308 had no defects and metallurgical bonding. The hardness of bimetal Q345/308 additive manufacturing samples was higher than that of Q345 or 308 single wire additive manufacturing. The sample made of Q345 single wire had serious electrochemical corrosion, while the sample made of 308 single wire had pitting corrosion. The pitting corrosion of the sample reinforced by bimetal Q345/308 feeding wires was improved.

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Kong, Camilla, Azfi Zaidi Mohammad Sofi, and Sarizam Mamat. "Advancements and Challenges in Wire Arc Additive Manufacturing – A Review." Malaysian Journal of Bioengineering and Technology (MJBeT) 1, no. 2 (December 18, 2024): 130–36. https://doi.org/10.70464/mjbet.v1i2.1474.

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Wire arc additive manufacturing (WAAM) is a groundbreaking advancement in 3D metal printing, enabling efficient and cost-effective production of large, complex components using gas tungsten arc welding (GTAW) and gas metal arc welding (GMAW). Suitable for metals like stainless steel, aluminium, and titanium alloys, WAAM involves layer-by-layer deposition of molten metal using an electric arc to melt wire feedstock. Despite its benefits, WAAM faces challenges with thermal cycles and microstructural inconsistencies, affecting component strength and ductility. Recent studies focus on microstructural analysis and mechanical properties, revealing varied microstructures due to distinct heat cycles. Research indicates consistent hardness across WAAM-fabricated components, with variations based on microstructural constituents. Optimizing the WAAM process involves understanding these characteristics and refining welding parameters. Advances in WAAM technology promise significant improvements in manufacturing efficiency, cost-effectiveness, and component quality across various industries.

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ELMER, JOHN W., GORDON GIBBS, JOHN S. CARPENTER, DANIEL R. COUGHLIN, PAT HOCHANADEL, JAY VAJA, PAROGYA GURUNG, ANDY JOHNSON, and MATTHEW J. DVORNAK. "Wire-Based Additive Manufacturing of Stainless Steel Components." Welding Journal 99, no. 1 (January 1, 2020): 8s—24s. http://dx.doi.org/10.29391/2020.99.002.

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Three different wire-fed additive manufacturing (AM) processes were employed to evaluate differences between laser, arc, and electron beam heat sources used for high-deposition-rate AM on the order of 1 kg/h. Optimum weld and build parameters were developed independently to match the characteristics of each heat source using 308L stainless steel welding wire as the feedstock. Laser-wire AM was made with the lowest energy per unit length of weld and had the best control of the melt pool and surface finish. Wire arc-based AM had an intermediate energy per unit length of weld of approximately 5× that of the laser process, while electron beam wire AM had the highest energy per unit length of weld at approximately 10× that of the laser process. Analysis of the parts that were built included evaluation of mechanical properties and microstructures, and these properties are discussed with respect to the difference in input energy and cooling rates. Results show that all three processes build parts with properties that exceed those of annealed 304L wrought stainless steel. How-ever, significant differences exist between the processes, and the results presented here can be used to help select the best wire-fed process for a given high-deposition-rate application.

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Journal articles on the topic 'Wire Arc Additive Manufactoring'

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