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In order to decrease mass, and thus fulfil the targets for airplane traffic emission reduction, the amount of titanium alloys used for structural components is rising. With the conventional milling process, low material utilization and short tool life lead to high manufacturing costs. Therefore, a process chain consisting of wire and arc additive manufacturing (WAAM) and machining is developed. To realize its full potential, the machining process needs to be adapted to the near-net shaped components. A special focus lies on the machining allowance, since it influences both processes and in result the final part quality. In this paper a method to model the machining allowance is proposed and verified by analysing the changes from waviness to surface roughness occurring during peripheral milling of WAAM parts.

Kurzfassung Hohe Werkzeugkosten und ein geringer Materialausnutzungsgrad führen zu hohen Produktionskosten für die Fertigung von Flugzeug-Strukturkomponenten aus der Legierung Ti 6Al 4V. Das Forschungsprojekt REGULUS hat zum Ziel, eine Prozesskette zu entwickeln, welche die Situation bezüglich dieser Kostentreiber signifikant verbessert. Dazu wird mittels WAAM ein endkonturnahes Rohteil aufgebaut. Die Zielgeometrie wird anschließend mit speziell für die Zerspanung unter ungleichmäßigen Eingriffsverhältnissen entwickelten Frässtrategien erzeugt.

As one of the most common Titanium alloys, Ti-6Al-4V faces new challenges concerning the ecological footprint. Due to the current processes, a high metal chip pollution leads to a Buy-to-Fly of 25:1. In this study the parameter / microstructure relationship of Ti-64 on the mechanical properties are discussed. Wire Arc Additive Manufacturing (WAAM) was applied to build samples for microstructural analyses and compression tests. A stress relief (SR) and a solution treatment and annealing (STA) was performed. It was found that SR had no influence on multi-layered samples due to intrinsic heat-treatment. A STA heat-treatment led to a reduction in the mechanical strength. Helium as process gas resulted in an increased mechanical strength due to higher heat capacity compared to argon.

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