A Comparison of Energy Consumption in Wire-based and Powder-based Additive-subtractive Manufacturing

Jackson, Marcus; Asten, Arik Van; Morrow, Justin D.; Min, Sangkee; Pfefferkorn, Frank E.

doi:10.1016/j.promfg.2016.08.087

Cited by 72 publications

(23 citation statements)

References 24 publications

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“…Additive Manufacturing (AM) technologies build up materials layer by layer, allowing complex shapes to be produced. Among various processes in AM, wire-base techniques show a lower energy requirement, about 85%, than those based on powder [1,2]. For Wire and Arc Additive Manufacturing (WAAM) technology, several modes of energy distribution are available according to suppliers.…”

Section: Introductionmentioning

confidence: 99%

Process Parameters Effect on Weld Beads Geometry Deposited by Wire and Arc Additive Manufacturing (WAAM)

Manokruang¹,

Vignat²,

Museau³

et al. 2021

Lecture Notes in Mechanical Engineering

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Among 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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Section: Introductionmentioning

confidence: 99%

Process Parameters Effect on Weld Beads Geometry Deposited by Wire and Arc Additive Manufacturing (WAAM)

Manokruang¹,

Vignat²,

Museau³

et al. 2021

Lecture Notes in Mechanical Engineering

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“…Thus, the initial investment is lower compared to other metals AM processes 1) . Furthermore, it has several advantages, including a high-efficiency energy source 5) , high deposition rate of 1-10 kg/h 6) , large lot size 7) , and high modifiability 1) . In addition, the WAAM process involves the stacking of weld beads based on the component design obtained using CAD/CAM software.…”

Section: Dimension Precision and Uniformability Depending On The Interpass Distance Variation Of Automated-wire Arc Additive Manufacturinmentioning

confidence: 99%

“…WAAM is a stacking process based on the repetitive conventional arc welding to build components. Thus, major process parameters of arc welding are basically significantly affect the performance of the WAAM process; such as the current, the voltage, contact tip to work distance (CTWD), travel speed, torch and travel angles, and shielding gas, etc 1,[5][6][7] . Meanwhile, in addition to these parameters, there are additional important process parameters; such as the interpass and interlayer distance, since the fabricated components consist of stacked individual beads 1,[8][9][10] .…”

Section: Dimension Precision and Uniformability Depending On The Interpass Distance Variation Of Automated-wire Arc Additive Manufacturinmentioning

confidence: 99%

Dimension Precision and Uniformability Depending on the Interpass Distance Variation of Automated-Wire Arc Additive Manufacturing using 5 Cr-4 Mo Tool Steel Alloy

Kim

Cheon

et al. 2021

Journal of Welding and Joining

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Die casting molds for aluminum are fabricated using machining billets of tool steels, such as Cr-Mo tool steel. However, this approach has several limitations, including significant material loss and a long lead time. Wire arc additive manufacturing (WAAM) is an alternative fabrication method that yields low material loss and has a short lead time. However, WAAM involves the repetitive stacking of layers based on designed tool paths using CAD/CAM. Thus, the predictability and uniformability of each layer are the most important factors. The interpass distance is an important parameter in a given process; however, studies on the interpass distance of the WAAM process are limited. In this study, it was determined that the interpass distance significantly influences the arc stability owing to the arc interference induced by the variation in distance from the prior deposited pass; more arc interference was observed as the interpass distance decreased. This phenomenon was validated via analysis using a high-speed camera and the variation in the amount of spatter. Furthermore, it was observed that the interpass distance influences the dimensional precision and uniformability. The interpass distance influences the arc interference unless it is greater than 100%. Thus, it is important to determine a point of balance based on the arc stability, dimension predictability, and uniformability of each layer.

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“…It is possible to decrease the energy consumption if the AM machine is used at full time and capacity (Faludi et al, 2015), if the machine idle/off state can be optimized (Faludi et al, 2016), and if the geometry and the position in the machine are correct (Verma and Rai, 2017). Other energy consumption factors consist of removing the part from the platform (Kellens et al, 2017) and improving the component surface with subtracting processes (Jackson et al, 2016); some EBM components can be separated by hand (Baumers et al, 2016). The social perspectives: While there is some research on the environmental implications of AM, the social dimension is largely absenting in previous analyses.…”

Section: Energy Consumptionmentioning

confidence: 99%

Additive Manufacturing From a Strategic Sustainability Perspective

Villamil¹,

Nylander²,

Hallstedt³

et al. 2018

Design Conference Proceedings

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There are high expectations of additive manufacturing (AM) as a technology to improve manufacturing efficiency and reduce material waste. This study aims to clarify the sustainability advantages and challenges of AM technologies used in industry by testing and applying a strategic sustainability life cycle assessment in the early development stage. The result showed possibilities from using the tool and some areas of certain interest regarding improvement potentials of the AM technologies, i.e. value chain management, concept design, optimized material usage, and social sustainability.

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A Comparison of Energy Consumption in Wire-based and Powder-based Additive-subtractive Manufacturing

Cited by 72 publications

References 24 publications

Process Parameters Effect on Weld Beads Geometry Deposited by Wire and Arc Additive Manufacturing (WAAM)

Process Parameters Effect on Weld Beads Geometry Deposited by Wire and Arc Additive Manufacturing (WAAM)

Dimension Precision and Uniformability Depending on the Interpass Distance Variation of Automated-Wire Arc Additive Manufacturing using 5 Cr-4 Mo Tool Steel Alloy

Additive Manufacturing From a Strategic Sustainability Perspective

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