Controls and process planning strategies for 5-axis laser directed energy deposition of Ti-6Al-4V using an 8-axis industrial robot and rotary motion

Gibson, Brian T.; Mhatre, Paritosh; Borish, Michael; Atkins, Celeste E.; Potter, John T.; Vaughan, Joshua; Love, Lonnie J.

doi:10.1016/j.addma.2022.103048

Cited by 14 publications

(3 citation statements)

References 63 publications

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“…The substrate tilting allows the deposition head to be fixed in a vertical position and always deposited on a horizontal surface. This solution is helpful because it prevents the molten pool from dropping on the sides of the component during the construction of the sloping walls [29]. Furthermore, the deposition head in the gantry-based machine can only translate but not rotate, making this the sole possible method for component realization.…”

Section: Case Study Definition and Realizationmentioning

confidence: 99%

“…Starting from the bottom, the component is made up of three major sectors that reflect various deposition modalities: • Sector A (standard vertical deposition): the base of the component is realized keeping the substrate horizontal; • Sector B (multi-axis deposition): the substrate tilts following the curvature of the main body of the component, maintaining a flat working plane in the deposition area; • Sector C (deposition on already deposited component): the substrate tilts at 90° to allow the deposition of a flange on the outer side of the already deposited component.The substrate tilting allows the deposition head to be fixed in a vertical position and always deposited on a horizontal surface. This solution is helpful because it prevents the molten pool from dropping on the sides of the component during the construction of the sloping walls[29]. Furthermore, the deposition head in the gantry-based machine can only translate but not rotate, making this the sole possible method for component realization.…”

mentioning

confidence: 99%

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Comparison between Eight-Axis Articulated Robot and Five-Axis CNC Gantry Laser Metal Deposition Machines for Fabricating Large Components

Maffia

Chiappini²,

Maggiani³

et al. 2023

Applied Sciences

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Laser metal deposition (LMD) is an additive manufacturing (AM) process capable of producing large components for the aerospace and oil and gas industries. This is achieved by mounting the deposition head on a motion system, such as an articulated robot or a gantry computer numerical control (CNC) machine, which can scan large volumes. Articulated robots are more flexible and less expensive than CNC machines, which on the other hand, are more accurate. This study compares two LMD systems with different motion architectures (i.e., an eight-axis articulated robot and a five-axis CNC gantry machine) in producing a large gas turbine axisymmetric component. The same process parameters were applied to both machines. The deposited components show no significant differences in geometry, indicating that the different performances in terms of accuracy of the two machines do not influence the outcome. The findings indicate that LMD can consistently produce large-scale axisymmetric metal components with both types of equipment. For such an application, the user has the option of using an articulated robot when flexibility and cost are essential, such as in a research context, or a CNC machine where ease of programming and process standardization are important elements, such as in an industrial environment.

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Section: Case Study Definition and Realizationmentioning

confidence: 99%

mentioning

confidence: 99%

Comparison between Eight-Axis Articulated Robot and Five-Axis CNC Gantry Laser Metal Deposition Machines for Fabricating Large Components

Maffia

Chiappini²,

Maggiani³

et al. 2023

Applied Sciences

View full text Add to dashboard Cite

show abstract

“…The basic idea is to use the robotic system to keep vector b vertical such that the melting pool remains horizontal with the previously built wall below [15,16]. Usually, the tool axis T is set coaxial with b or may be inclined with constant lead and tilt angles.…”

Section: Trajectory Generation Stage: Iso-height Layer Deposition Pat...mentioning

confidence: 99%

Manufacturing of a Schwarz-P pattern by multi-axis WAAM

et al. 2023

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Emerging trends in large format additive manufacturing processes and hybrid techniques

Vanerio,

Guagliano,

Bagherifard

2024

Prog Addit Manuf

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Large format additive manufacturing (LFAM) technologies are rapidly growing with significant potential for application in multiple technological sectors like aerospace, tooling, automotive, marine, construction, and energy. LFAM processes offer significant advantages including reduced lead time, cost, and material waste, which are further amplified due to the increased volume of the components. This review paper focuses on LFAM technologies with the highest technology readiness level, i.e., metal Directed Energy Deposition (DED), polymer extrusion, and solid-state deposition (i.e. cold spray additive manufacturing (CSAM)). Common system setups, the maximum deposition rate, and the range of processable materials, along with the achievable mechanical properties and geometrical characteristics, are outlined for each technology, both in individual and hybrid manufacturing formats. The main technological challenges are gathered and discussed to highlight the areas that require further development. Finally, the current industrial applications for LFAM technologies and the expected future developments are outlined. This review provides an overview of LFAM technologies’ current status and discusses their potential in improving the manufacturing of complex and large geometries, with a significant reduction in material and energy consumption, while ensuring high-quality and high-performance components.

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Controls and process planning strategies for 5-axis laser directed energy deposition of Ti-6Al-4V using an 8-axis industrial robot and rotary motion

Cited by 14 publications

References 63 publications

Comparison between Eight-Axis Articulated Robot and Five-Axis CNC Gantry Laser Metal Deposition Machines for Fabricating Large Components

Comparison between Eight-Axis Articulated Robot and Five-Axis CNC Gantry Laser Metal Deposition Machines for Fabricating Large Components

Manufacturing of a Schwarz-P pattern by multi-axis WAAM

Emerging trends in large format additive manufacturing processes and hybrid techniques

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