3D‐Drucken im Stahlbau mit dem automatisierten Wire Arc Additive Manufacturing

Feldmann, Markus; Kühne, Ronny; Citarelli, Sandro; Reisgen, Uwe; Sharma, Rahul; Oster, Lukas Emmanuel

doi:10.1002/stab.201800029

Cited by 20 publications

(15 citation statements)

References 10 publications

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“…With a view to future developments in architecture and construction, customized connections between different components made of different materials are required and gain importance. The new approaches of additive manufacturing in construction enable the free architectural design of steel components, such as thin shells [1] and complex force flow-optimized steel nodes [2][3][4]. For the manufacturing of those steel nodes, there is a variety of additive manufacturing technologies.…”

Section: Introductionmentioning

confidence: 99%

Mechanical properties of wire and arc additively manufactured high-strength steel structures

2021

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Additive manufacturing with steel opens up new possibilities for the construction sector. Especially direct energy deposition processes like DED-arc, also known as wire arc additive manufacturing (WAAM), is capable of manufacturing large structures with a high degree of geometric freedom, which makes the process suitable for the manufacturing of force flow-optimized steel nodes and spaceframes. By the use of high strength steel, the manufacturing times can be reduced since less material needs to be deposited. To keep the advantages of the high strength steel, the effect of thermal cycling during WAAM needs to be understood, since it influences the phase transformation, the resulting microstructure, and hence the mechanical properties of the material. In this study, the influences of energy input, interpass temperature, and cooling rate were investigated by welding thin walled samples. From each sample, microsections were analyzed, and tensile test and Charpy-V specimens were extracted and tested. The specimens with an interpass temperature of 200 °C, low energy input and applied active cooling showed a tensile strength of ~ 860–900 MPa, a yield strength of 700–780 MPa, and an elongation at fracture between 17 and 22%. The results showed the formation of martensite for specimens with high interpass temperatures which led to low yield and high tensile strengths (Rp0.2 = 520–590 MPa, Rm = 780–940 MPa) for the specimens without active cooling. At low interpass temperatures, the increase of the energy input led to a decrease of the tensile and the yield strength while the elongation at fracture as well as the Charpy impact energy increased. The formation of upper bainite due to the higher energy input can be avoided by accelerated cooling while martensite caused by high interpass temperatures need to be counteracted by heat treatment.

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Section: Introductionmentioning

confidence: 99%

Mechanical properties of wire and arc additively manufactured high-strength steel structures

2021

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“…The second use case involved structures of variable tensile strength. This might be interesting for architectural applications and steel construction, with WAAM for large-scale structures currently being investigated [37][38][39]. The possibility to change the tensile strength where geometric restrictions require a reduction of the load-bearing cross section may lead to greater freedom of design in the construction process.…”

Section: Methodsmentioning

confidence: 99%

Plasma Multiwire Technology with Alternating Wire Feed for Tailor-Made Material Properties in Wire and Arc Additive Manufacturing

Reisgen

Sharma

Oster

2019

Metals

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Wire and arc additive manufacturing (WAAM) is one of the most promising technologies for large-scale 3D printing of metal parts. Besides the high deposition rates, one of the advantages of WAAM is the possibility of using in situ alloying to modify the chemical composition and therefore the material properties of the fabricated workpiece. This can be achieved by feeding multiple wires of different chemical compositions into the molten pool of the welding process and generating a new alloy during the manufacturing process itself. At present, the chemical composition is changed stepwise by keeping the wire feed speeds per layer constant. This article describes the possibilities of generating chemically graded structures by constantly alternating the wire feed speeds of a multiwire WAAM process. This enables the chemical composition to be smoothly changed during the printing process, and generating structures with highly complex material properties. Several material combinations for different possible applications were successfully tested. Furthermore, grading strategies to avoid negative influences of low-ductility intermetallic phases were examined. The results show that low-ductility phases may even have a beneficial influence on the fracture behavior if they are combined with ductile phases. Moreover, prospective possible applications are discussed.

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“…Adapted material development for powder-based materials with little effort is possible by mixing the powders accordingly [4][5][6][7]. Wire-based additive manufacturing by means of an arc, also known as wire arc additive manufacturing, requires a welding filler material in wire form [8][9][10]. A corresponding alloy development up to the wire-shaped welding filler material is very costly.…”

Section: Introductionmentioning

confidence: 99%

Development of an Alternative Alloying Concept for Additive Manufacturing Using PVD Coating

2022

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New alloys are needed to adapt the material properties and to improve the weldability of arc-based additive manufacturing processes. The classic development of welding filler materials is time-consuming and cost-intensive. For this reason, an alternative alloy concept is investigated and qualified here. This is based on the thin-film coating of welding filler materials by means of PVD coating. An HSLA steel DIN EN ISO 14341-A G 50 7 M21 is used as the base material. This is alloyed with the elements Al, Cr, Nb, Ni and Ti by means of PVD thin-film coating. This procedure represents an alternative alloy concept. In the scope of the qualification, the influence of the process and material properties is investigated, and the alternative alloying concept is compared with the classical alloying concept of secondary metallurgy. The investigations have shown that the thin film coating on the surface of the welding filler metal affects the process properties in the form of a changed arc length. Furthermore, the mechanical properties and the effect on the microstructure morphology were investigated. These were compared in the same chemical composition with a Mn4Ni2CrMo produced by secondary metallurgy. The results are in agreement with regard to the mechanical properties and the effect on the microstructure morphology.

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3D‐Drucken im Stahlbau mit dem automatisierten Wire Arc Additive Manufacturing

Cited by 20 publications

References 10 publications

Mechanical properties of wire and arc additively manufactured high-strength steel structures

Mechanical properties of wire and arc additively manufactured high-strength steel structures

Plasma Multiwire Technology with Alternating Wire Feed for Tailor-Made Material Properties in Wire and Arc Additive Manufacturing

Development of an Alternative Alloying Concept for Additive Manufacturing Using PVD Coating

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