Multi-Material Design in Welding Arc Additive Manufacturing

Abstract

Due to the inherent properties of the process, arc-based generative manufacturing offers the possibility, of specifically applying different material properties locally. One possibility to realize this is the use of different materials. Three approaches are presented to illustrate this option. First, anisotropic behavior in the welding direction is generated. For this purpose, a FeNi36 is specifically combined with a low-alloy ultra-high-strength fine-grained structural steel filler metal. It will be shown that the integral component properties can be specifically adjusted in the welding direction. In addition, the metallurgical and welding characteristics will be discussed. As a second possibility, the use of well plasticizable materials to locally increase the material strength under cyclic loading with locally notched components is presented. For this purpose, an austenitic FeNi36 with good plasticizability and a good yield strength ratio for the application was applied to a fillet weld of a high-strength fine-grained structural steel in the weld seam toe. It is shown that the tolerable cyclic load can be improved by 35% by this procedure. Thirdly, it is shown that the required thickness of corrosion protection layers can be reduced by 50% through a targeted production sequence in arc-based generative manufacturing.

Technical Challenges and Future Environmentally Sustainable Applications for Multi-Material Additive Manufacturing for Metals

“…On one hand, when planning product fabrication for additive manufacturing, often the focus is on design shape complexity (e.g., "solid-to-cavity ratio" [1,19,42,43]), and lightweight and strength (e.g., "strength-to-weight ratio" [44]). In particular, there are studies illustrating the potential of multi-material additive manufacturing to enhance product strengths and prolong its lifetime [20,21] which are beneficial aspects in relation to circular economy. On the other hand, there is a general lack of argument relating to how product recyclability design can or should be applied to multi-material additive manufacturing.…”

“…From both a sustainability or recycling, and technical point of views, MM-WAAM still faces various challenges. The primary reason is that the materials are not easily differentiated into the different waste streams, thus reducing the recycling quality, and layering different alloys constitute a challenge [20,21].…”

Wire and Arc Additive Manufacturing of a CoCrFeMoNiV Complex Concentrated Alloy Using Metal-Cored Wire—Process, Properties, and Wear Resistance

“…This process allows a large variety in geometries to be manufactured, including overhangs [15,16]. Furthermore, it can be used for a wide range of materials and also multi-material and functionally graded approaches [17][18][19][20][21][22][23][24][25]. In this case, the manufacturing process could have a significant impact on the properties of the materials that are summarized and shown in [13,26,27] and need to be considered for the prediction of the material properties.…”

Effect of the Heat Input on Wire-Arc Additive Manufacturing of Invar 36 Alloy: Microstructure and Mechanical Properties

“…In previous literature, only GMAW-based WAAM process was studied for Invar manufacturing [17]. Finally, in some studies, Invar alloy is combined with structural steel thanks to the WAAM process to adapted locally the mechanical properties of the deposited material [18,19].…”