Design strategies for bi-metallic additive manufacturing in the context of wire and arc directed energy deposition

Marefat, Fereidoon; Pauw, Joeri De; Kapil, Angshuman; nvestigation, Nataliia Chernovol; Rymenant, Patrick Van; Sharma, Abhay

doi:10.1016/j.matdes.2022.110496

Cited by 9 publications

(6 citation statements)

References 19 publications

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“…For the deposition methods shown in Figure 1, different WAAM parameter values were used for the materials. The parameters were adjusted to avoid a lack of fusion and sufficient penetration by minimizing the heat input [15]. The heat input (HI) was calculated for each case using Equation (1), where k is the thermal efficiency factor of a specific welding process (k = 0.8, as per EN 1011-1), V is the arc voltage, I is the welding current, TS is the travel speed, H is the bead height, and W is the bead width.…”

Section: Experimental Procedures For Wire and Arc Additive Manufacturingmentioning

confidence: 99%

“…Studies on WAAM are generally limited to single-material deposits and their surface properties. Few studies have been conducted on producing multi-material components, even though the demand for such products has increased [15][16][17][18][19]. However, studies are generally limited to examining the appropriate parameter selection [17,18] or basic structural integrity criteria [19] for multi-material deposition.…”

Section: Introductionmentioning

confidence: 99%

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Machining Strategy Determination for Single- and Multi-Material Wire and Arc Additive Manufactured Thin-Walled Parts

2023

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Wire and arc additive manufacturing (WAAM) technology has recently become attractive due to the fact of its high production capacity and flexible deposition strategy. One of the most prominent drawbacks of WAAM is surface irregularity. Therefore, WAAMed parts cannot be used as built; they require secondary machining operations. However, performing such operations is challenging due to the fact of high waviness. Selecting an appropriate cutting strategy is also challenging, because surface irregularity makes cutting forces unstable. The present research determines the most suitable machining strategy by assessing the specific cutting energy and local machined volume. Up- and down-milling are evaluated by calculating the removed volume and specific cutting energy for creep-resistant steel, stainless steel, and their combination. It is shown that the main factors that affect the machinability of WAAMed parts are the machined volume and specific cutting energy rather than the axial and radial depths of the cut due to the fact of high surface irregularity. Even though the results were unstable, a surface roughness of 0.1 µm was obtained with up-milling. Despite a two-fold difference in the hardness between the two materials in the multi-material deposition, it is found that hardness should not be used as a criterion for as-built surface processing. In addition, the results show no machinability difference between multi- and single-material components for a low machined volume and low surface irregularity.

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Section: Experimental Procedures For Wire and Arc Additive Manufacturingmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Machining Strategy Determination for Single- and Multi-Material Wire and Arc Additive Manufactured Thin-Walled Parts

2023

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“…A reduced lead time and an increased mold life were reported, thus indicating the potential of the multimaterial injection molding process. In more recent work with the utilization of WAAM, the bi-metallic pairs LCS-SS [117] and CRS-SS [118,119] have been successfully fabricated. To manufacture titanium-based alloy and nickel-based alloy bi-metallic components (TC4-IN718), which are widely used in the aerospace industry due to their excellent characteristics, tantalum-copper interlayers were utilized by Wang et al [115] to prevent the formation of Ti-Ni and Ti-Cu compounds at the interface and thus form a good bond at the interface.…”

Section: Bi-metallic Componentsmentioning

confidence: 99%

“…A reduced lead time and an increased mold life were reported, thus indicating the potential of the multi-material injection molding process. In more recent work with the utilization of WAAM, the bi-metallic pairs LCS-SS [117] and CRS-SS [118,119] have been successfully fabricated.…”

Section: Bi-metallic Componentsmentioning

confidence: 99%

A Review on Multiplicity in Multi-Material Additive Manufacturing: Process, Capability, Scale, and Structure

et al. 2023

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Additive manufacturing (AM) has experienced exponential growth over the past two decades and now stands on the cusp of a transformative paradigm shift into the realm of multi-functional component manufacturing, known as multi-material AM (MMAM). While progress in MMAM has been more gradual compared to single-material AM, significant strides have been made in exploring the scientific and technological possibilities of this emerging field. Researchers have conducted feasibility studies and investigated various processes for multi-material deposition, encompassing polymeric, metallic, and bio-materials. To facilitate further advancements, this review paper addresses the pressing need for a consolidated document on MMAM that can serve as a comprehensive guide to the state of the art. Previous reviews have tended to focus on specific processes or materials, overlooking the overall picture of MMAM. Thus, this pioneering review endeavors to synthesize the collective knowledge and provide a holistic understanding of the multiplicity of materials and multiscale processes employed in MMAM. The review commences with an analysis of the implications of multiplicity, delving into its advantages, applications, challenges, and issues. Subsequently, it offers a detailed examination of MMAM with respect to processes, materials, capabilities, scales, and structural aspects. Seven standard AM processes and hybrid AM processes are thoroughly scrutinized in the context of their adaptation for MMAM, accompanied by specific examples, merits, and demerits. The scope of the review encompasses material combinations in polymers, composites, metals-ceramics, metal alloys, and biomaterials. Furthermore, it explores MMAM’s capabilities in fabricating bi-metallic structures and functionally/compositionally graded materials, providing insights into various scale and structural aspects. The review culminates by outlining future research directions in MMAM and offering an overall outlook on the vast potential of multiplicity in this field. By presenting a comprehensive and integrated perspective, this paper aims to catalyze further breakthroughs in MMAM, thus propelling the next generation of multi-functional component manufacturing to new heights by capitalizing on the unprecedented possibilities of MMAM.

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“…Furthermore, the innovative research in WAAM is driven by the need to deposit a variety of alloys and combinations of them in multi-material components, e.g. bimetallic [155] or functionally graded material structures [156]. One of the upcoming innovations is using a multi-wire torch to deposit two feed wires of the same or different compositions to control the weld bead's chemistry or shape [157].…”

Section: Hybrid Manufacturingmentioning

confidence: 99%

A Survey on Process Modelling, Innovation, Design, and Material Characterisation in Additive Manufacturing

Hassani

Emami

Tjahjowidodo

et al. 2023

Digital Manufacturing Technology

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The unique design freedom offered by additive manufacturing (AM) technologies enables engineers to develop more innovative products with relatively lower costs within a shorter period of processing time in comparison with conventional manufacturing methods. On the other hand, the unique capabilities of AM have created a platform for researchers to combine several engineering methods with the new manufacturing technique to grow industrial applications as well as resolve the existing issues with AM processes. Understanding the research values that AM offers academic environments, this paper performs a systematic survey on AM-related research topics in the fields of mechanical engineering and materials science that have attracted much attention from research teams over the last few years. These topics, namely process modelling in AM, innovative research in AM, generative design by AM, material characterisation in AM processes, and finally, design for additive manufacturing (DfAM), are notably investigated through this study.

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Design strategies for bi-metallic additive manufacturing in the context of wire and arc directed energy deposition

Cited by 9 publications

References 19 publications

Machining Strategy Determination for Single- and Multi-Material Wire and Arc Additive Manufactured Thin-Walled Parts

Machining Strategy Determination for Single- and Multi-Material Wire and Arc Additive Manufactured Thin-Walled Parts

A Review on Multiplicity in Multi-Material Additive Manufacturing: Process, Capability, Scale, and Structure

A Survey on Process Modelling, Innovation, Design, and Material Characterisation in Additive Manufacturing

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