Coordinate system setting for post-machining of impeller shape by wire arc DED and evaluation of processing efficiency

Abstract

Wire arc additive manufacturing (WAAM) is a direct energy deposition (DED) process that uses arc welding. It is a method of stacking beads made by melting metal wires with an arc heat source generated by a short-circuit current. Compared to other metal additive manufacturing methods, this process can be used to quickly produce large and complex-shaped metal parts. However, due to the multi-bead stacking method, the surface is highly curved and the dimensional errors are large; therefore, post-processing of the surface by cutting is required. Impellers, which are widely used in various industries, have complex shapes and high material consumption during cutting; therefore, the WAAM process can improve the manufacturing efficiency. In this study, a manufacturing process for an impeller with a diameter of 160 mm was developed by using the WAAM process. A 6-bladed fan-type impeller used for high-pressure fluid delivery was similarly modeled, and the product was additively manufactured using an Inconel 625 alloy wire. Manufacturing conditions that ensure productivity and quality or the product were determined through experimentation. Considering the post-processing of the WAAM-fabricated structure, the robot and tool paths of the impeller model were designed, and the error in the process coordinate system caused by attaching and detaching the workpiece between the two processes was reduced. Through the post-processing of the WAAM-fabricated structure, the production efficiency and process reliability were verified when the conventional manufacturing method and WAAM process were applied.