Applications of wire arc additive manufacturing (WAAM) for aerospace component manufacturing

Pant, Harshita; Arora, Anisha; Gopakumar, G; Chadha, Utkarsh; Saeidi, Amir; Patterson, Albert E.

doi:10.1007/s00170-023-11623-7

Cited by 40 publications

(5 citation statements)

References 111 publications

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“…The parameter 'a' in both functions describes the wire's initial deflection, which is always greater than 0 due to its curvature. In model (5), 'b' is responsible for the curve's slope, while 'c' is for its shape. In model (4), parameters 'b' and 'c' have a complex effect on the data distribution's shape.…”

Section: Wire Deviation Modelmentioning

confidence: 99%

“…The utilization of Wire and Arc Additive Manufacturing (WAAM) technology in contemporary production is determined by the requirement to accelerate and streamline the fabrication of distinctive metal components, along with enhancing environmental sustainability by reducing waste [1][2][3]. GMAW-based WAAM provides increased 3D printing efficiency [4] [5], but comes with the drawback of decreased precision and poor surface quality [6]. Printed parts typically necessitate additional machining, therefore minimizing post-processing is crucial for streamlining production time and simplifying the production chain [7,8].…”

Section: Introductionmentioning

confidence: 99%

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Filler wire deflection control for Wire and Arc Additive Manufacturing

Molochkov,

Kulykovskyi

2023

Preprint

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This paper examines the issue of wire deflection in Wire and Arc Additive Manufacturing (WAAM), which leads to process instability and defects in printed geometry. The study focuses on the deflection of Alloy 601/625, Inconel 718 and SG2 wires during the deposition process. Measurements were taken to determine the relationship between wire deflection and the amount of wire used. Regression models were developed for each material to predict initial wire deflection and changes in deflection due to contact tip wear. The results showed that the deflection of Alloy 601/625 and Inconel 718 wires followed a non-linear pattern for the first 500 meters of wire, while the deflection of SG2 wire followed a nearly linear trend. The intensity of the contact tip wear is dependent on the normal contact load, which decreases as the wear increases. Based on these models, an algorithm was developed to correct the wire deflection by adjusting the tool center point coordinates. The effectiveness of the developed algorithm was verified in practice.

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Section: Wire Deviation Modelmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Filler wire deflection control for Wire and Arc Additive Manufacturing

Molochkov,

Kulykovskyi

2023

Preprint

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“…Hardness, toughness, and room temperature tensile assessments are carried out to assess the mechanical characteristics of a printed alloy. Pant et al (2023) investigated the main aerospace industry application sectors where WAAM has been utilized with a few instances; some simulation work and modeling that has been done for WAAM that is pertinent to the aerospace industry, as well as existing state of the utilized WAAM substances were concentration to the aviation field. Omiyale et al (2022) examined and discussed in detail works related to the mechanical features, metallurgical features, and usage of WAAM of aluminum alloys for the automotive and aerospace industries.…”

Section: Introductionmentioning

confidence: 99%

Assessing the pros and cons of wire-arc additive manufacturing for material production

Singh,

Venkadeshwaran,

Singh

et al. 2024

Multidiscip. Rev.

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A promising new method for mass-producing metal components and structures for a range of industries, including shipbuilding, automotive, aviation, and other technical sectors, is wire arc additive manufacturing (WAAM). Additive manufacturing (AM) called 3D printing, it is a disruptive manufacturing technique that starts with digital design data and manufactures products layer by layer. WAAM has been utilized to create parts from a variety of materials, such as alloy wires based on aluminium (Al), titanium (Ti) and nickel. This review article focuses on the most important facets of the WAAM process, including the technology utilized, the drawbacks encountered, the steps taken during and after the process, the tools used to monitor the process, the gases involved, and the materials. The comparison of WAAM with other additive manufacturing technologies is also emphasized in the article. Moreover, it compares and analyses several WAAM techniques, including plasma arc welding (PAW), gas metal arc welding (GMAW) and gas tungsten arc welding (GTAW) in terms of material deposition rate, the method GMAW have higher material deposition rate when compared to other approach. Material manufacturing using WAAM has great potential. The accuracy of the manufacturing and smoothness of WAAM-made parts can be enhanced in the future to better suit tight-tolerance uses.

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“…Some common applications of PLA include medical devices [21], dental implants [22,23], and food service products [24,25]. When constrained by the dimensions of the additive manufacturing platform [26], it is common practice to divide a substantial medical device into multiple segments for printing, necessitating subsequent assembly.…”

Section: Introductionmentioning

confidence: 99%

Enhancing the Weld Quality of Polylactic Acid Biomedical Materials Using Rotary Friction Welding

Kuo,

Liang,

Huang

et al. 2024

Polymers

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Polylactic acid (PLA) stands out as a biomaterial with immense potential, primarily owing to its innate biodegradability. Conventional methods for manufacturing PLA encompass injection molding or additive manufacturing (AM). Yet, the fabrication of sizable medical devices often necessitates fragmenting them into multiple components for printing, subsequently requiring reassembly to accommodate the constraints posed by the dimensions of the AM platform. Typically, laboratories resort to employing nuts and bolts for the assembly of printed components into expansive medical devices. Nonetheless, this conventional approach of jointing is susceptible to the inherent risk of bolts and nuts loosening or dislodging amid the reciprocating movements inherent to sizable medical apparatus. Hence, investigation into the joining techniques for integrating printed components into expansive medical devices has emerged as a critical focal point within the realm of research. The main objective is to enhance the joint strength of PLA polymer rods using rotary friction welding (RFW). The mean bending strength of welded components, fabricated under seven distinct rotational speeds, surpasses that of the underlying PLA substrate material. The average bending strength improvement rate of welding parts fabricated by RFW with three-stage transformation to 4000 rpm is about 41.94% compared with the average bending strength of PLA base material. The average surface hardness of the weld interface is about 1.25 to 3.80% higher than the average surface hardness of the PLA base material. The average surface hardness of the weld interface performed by RFW with variable rotational speed is higher than the average surface hardness of the weld interface performed at a fixed rotating friction speed. The temperature rise rate and maximum temperature recorded during RFW in the X-axis of the CNC turning machine at the outer edge of the welding part surpassed those observed in the internal temperature of the welding part. Remarkably, the proposed method in this study complies with the Sustainable Development Goals due to its high energy efficiency and low environmental pollution.

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Applications of wire arc additive manufacturing (WAAM) for aerospace component manufacturing

Cited by 40 publications

References 111 publications

Filler wire deflection control for Wire and Arc Additive Manufacturing

Filler wire deflection control for Wire and Arc Additive Manufacturing

Assessing the pros and cons of wire-arc additive manufacturing for material production

Enhancing the Weld Quality of Polylactic Acid Biomedical Materials Using Rotary Friction Welding

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