Open-source wire and arc additive manufacturing system: formability, microstructures, and mechanical properties

Lu, Xin; Zhou, Yefei; Xing, Xiaolei; Shao, Liping; Yang, Qingxiang; Gao, Shiyou

doi:10.1007/s00170-017-0636-z

Cited by 98 publications

(27 citation statements)

References 14 publications

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“…As property anisotropy is undesirable, layer building strategies on the mechanical properties of printed part have been the main focus of several works. The effect of anisotropy was also confirmed by Lu et al [15], whose results exhibited better mechanical property with specimens perpendicular to the building direction. A literature review about the effects of test orientation/build direction on properties was provided by Lewandowski and Seifi [16], along with discussion of the potential sources, e.g., texture, microstructure changes, and defects.…”

Section: Introductionsupporting

confidence: 62%

Exploring the use of switchback for mitigating homoepitaxial unidirectional grain growth and porosity in WAAM of aluminium alloys

Yehorov

Silva

Scotti

2019

Int J Adv Manuf Technol

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In this work, an alternative approach to prevent unidirectional grain growth in wire + arc additive manufacturing (WAAM) is proposed and assessed, by moving cyclically the torch forward and backward, likewise the welding technique known as switchback. A series of tests were planned with CMT (cold metal transfer) process to compare three wall-like build-ups, which uses different deposition patterns, namely, in one-way direction, reverse direction, and switchback. The same equivalent travel speed and number of deposited layers were kept among them. Longitudinal sections were taken to identify the grain growth behaviour. Finally, samples were removed from the walls for porosity evaluation. The results confirmed the characteristics of unidirectional grain growth, when one-way direction condition was employed, and the break of growth direction between layers, when reverse direction was used, yet a zigzag pattern became present. Differently, the application of switchback showed no preferential or unidirectional grain growth, suggesting less anisotropy of mechanical properties. In addition, switchback reduced porosity.

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Section: Introductionsupporting

confidence: 62%

Exploring the use of switchback for mitigating homoepitaxial unidirectional grain growth and porosity in WAAM of aluminium alloys

Yehorov

Silva

Scotti

2019

Int J Adv Manuf Technol

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“…For example, the axe head would require 30 min of pause time between layers if it were 100% filled, but it is hollow, so only 15 min needed. One approach recently shown by Lu et al to partially address this challenge is to use active cooling [57]. Cooling down the part reduces the pause time necessary for the 3-D printer in between layers.…”

Section: Discussionmentioning

confidence: 99%

“…Cooling down the part reduces the pause time necessary for the 3-D printer in between layers. In addition, Lu et al 's results indicate that the formability of metal parts fabricated with an open-source wire and arc additive manufacturing (WAAM) system were improved with compulsory cooling [57].…”

Section: Discussionmentioning

confidence: 99%

Applications of Open Source GMAW-Based Metal 3-D Printing

Nilsiam

Sanders

Pearce

2018

JMMP

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The metal 3-D printing market is currently dominated by high-end applications, which make it inaccessible for small and medium enterprises, fab labs, and individual makers who are interested in the ability to prototype and additively manufacture final products in metal. Recent progress led to low-cost open-source metal 3-D printers using a gas metal arc welding (GMAW)-based print head. This reduced the cost of metal 3-D printers into the range of desktop prosumer polymer 3-D printers. Consequent research established good material properties of metal 3-D printed parts with readily-available weld filler wire, reusable substrates, thermal and stress properties, toolpath planning, bead-width control, mechanical properties, and support for overhangs. These previous works showed that GMAW-based metal 3-D printing has a good adhesion between layers and is not porous inside the printed parts, but they did not proceed far enough to demonstrate applications. In this study, the utility of the GMAW approach to 3-D printing is investigated using a low-cost open-source metal 3-D printer and a converted Computer Numerical Control router machine to make useful parts over a range of applications including: fixing an existing part by adding a 3-D metal feature, creating a product using the substrate as part of the component, 3-D printing in high resolution of useful objects, near net objects, and making an integrated product using a combination of steel and polymer 3-D printing. The results show that GMAW-based 3-D printing is capable of distributed manufacturing of useful products for a wide variety of applications for sustainable development.

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“…This development was made possible, among other things, by new welding process variants in the short arc range [9][10][11] developed in recent decades, as well as by findings regarding the importance of welding sequence and energy input on the shape accuracy and the mechanical properties occurring in the material, [12][13][14][15].…”

Section: Introductionmentioning

confidence: 99%

Multi-Material Design in Welding Arc Additive Manufacturing

Treutler

Kamper

Leicher

et al. 2019

Metals

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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.

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Open-source wire and arc additive manufacturing system: formability, microstructures, and mechanical properties

Cited by 98 publications

References 14 publications

Exploring the use of switchback for mitigating homoepitaxial unidirectional grain growth and porosity in WAAM of aluminium alloys

Exploring the use of switchback for mitigating homoepitaxial unidirectional grain growth and porosity in WAAM of aluminium alloys

Applications of Open Source GMAW-Based Metal 3-D Printing

Multi-Material Design in Welding Arc Additive Manufacturing

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