Parameter Selection for Wire Arc Additive Manufacturing (WAAM) Process

Wahsh, L.; Azzam, Mohamed; Turky, M.; Salem, H.; Hamdy, F.; Mansour, Ayman; ElShater, A.

doi:10.7449/2018/mst_2018_78_85

Cited by 9 publications

(4 citation statements)

References 5 publications

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“…Moreover, it forms a fine low melting eutectic structure that can backfill cracks and increase the grain boundary area, preventing crack growth [244]. Among aluminium alloys, AlSi10Mg is the most extensively AM-fabricated alloy [68,71,72,248,249], although others like Al 5356 [250][251][252][253] and Al 4043 [254][255][256][257] have also been studied. The alloy is a hypoeutectic Al-Si alloy with a composition close to eutectic.…”

Section: Aluminium Alloysmentioning

confidence: 99%

Large-scale metal additive manufacturing: a holistic review of the state of the art and challenges

Lehmann

Rose

Ranjbar

et al. 2021

International Materials Reviews

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Additive Manufacturing (AM) has the potential to completely reshape the manufacturing space by removing the geometrical constraints of commercial manufacturing and reducing component lead time, especially for large-scale parts. Coupling robotic systems with direct energy deposition (DED) additive manufacturing techniques allow for support-free printing of parts where part sizes are scalable from sub-metre to multi-metre sizes. This paper offers a holistic review of large-scale robotic additive manufacturing, beginning with an introduction to AM, followed by different DED techniques, the compatible materials and their typical as-built microstructures. Next, the multitude of robotic build platforms that extend the deposition from the standard 2.5 degrees of freedom (DOF) to 6 and 8 DOF is discussed. With this context, the decomposition and slicing of the computerized model will be described, and the challenges of planning the deposition trajectory will be discussed. The different modalities to monitor and control the deposition in an attempt to meet the geometrical and performance specifications are outlined and discussed. A wide range of metals and alloys have been reported and evaluated for large-scale AM parts. These include steels, Ti, Al, Mg, Cu, Ni, Co-Cr and W alloys. Different post-processing steps, including heat treatments, are discussed, along with their microstructures. This paper finally addresses the authors' perspective on the future of the field and the largest knowledge gaps that need to be filled before the commercial implementation of robotic AM.

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Section: Aluminium Alloysmentioning

confidence: 99%

Large-scale metal additive manufacturing: a holistic review of the state of the art and challenges

Lehmann

Rose

Ranjbar

et al. 2021

International Materials Reviews

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“…and 4.67 mm for the first level, second level, third level simulation, respectively. In addition, a welding speed influences the rate of heat input and welding penetration [23][24] and [25]. Overall, the above response table shows that welding speed is the most crucial factor in the welding process, which is influenced by the percentage factor contribution obtained from the ANOVA study [26].…”

Section: S/n Ratiomentioning

confidence: 99%

Simulation of wire and arc additive manufacturing of 308L stainless steel with cold arc gas metal arc welding

Hussein¹,

Jmmani²,

Ayof³

et al. 2021

JAEDS

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This research focuses on the capabilities of coldArc GMAW in the behavior of heat input to the weld bead dimension. In this study, the effect of process GMAW of 308L stainless steel filler wire with a thickness of 1.2 mm and 304L stainless steel base plate, with a dimension of 120 mm x 25 mm x 10 mm (height x width x thickness) by applying WAAM. The data was collected using MATLAB of a Smart Weld Rosenthal’s Steady-State 3D Isotherms. A Taguchi response was used in the DOE method with Minitab software to analyze the effect of process parameters on height, width, and depth of weld bead dimension during GMAW. The experiments were conducted following the low, mid, and high input parameters will show the different structures of weld bead dimension, which include 70 A, 75 A, and 78 A (arc current), 15 V, 16 V, and 17 V (voltage), 400 mm/min, 600 mm/min, and 800 mm/min (welding speed). Hence, the optimum value is 75 A, 16 V, and 800 mm/min, and the most significant parameters to deposit stainless steel with coldArc GMAW were welding speed followed by arc current and voltage.

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“…This applies to both the directly aged condition and the solution treated + aged conditions, as demonstrated in the case of 17-4 PH stainless steel [28]. Numerous studies have focused on optimizing the parameters of the incremental welding process [29]. These studies primarily assess the impact of current parameters, heat input, and welding trajectory.…”

Section: Introductionmentioning

confidence: 99%

Effect of the Electrode Extension on the Geometry of Parts Made of 316LSi Steel by Wire Arc Additive Manufacturing Method (WAAM)

Połaski,

Golański,

Kołodziejczak

et al. 2024

Adv. Sci. Technol. Res. J.

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Intensive research is currently being conducted on wire arc additive manufacturing (WAAM) processes. Previous studies have demonstrated the impact of current parameters on altering the structure and properties of 316L stainless steel. However, there is a lack of comprehensive information in the literature regarding the influence of electrode extension length (contact to tube distance) on changes in the structure and geometry of parts made of 316L steel using the cold metal transfer (CMT) method. This parameter was often assumed to be constant in research experiments. The study aimed to determine how the length of the electrode extension affects the geometric properties of steel walls produced in the WAAM CMT additive manufacturing process. The experiment used 316LSi stainless steel to build 3D structures in the shape of straight walls. The chosen shape of the parts yielded the most benefits for preparing samples from the resulting structures for destructive testing. The research demonstrated that the length of the electrode extension is a crucial parameter in the additive manufacturing process of structures using the WAAM method. Modifying the electrode extension length in the WAAM process with a CMT machine impacts the bead geometry and, consequently, the overall model geometry. A 6 mm increase in the electrode extension length resulted in a model that was over 8 mm taller, despite using the same number of layers.

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Parameter Selection for Wire Arc Additive Manufacturing (WAAM) Process

Cited by 9 publications

References 5 publications

Large-scale metal additive manufacturing: a holistic review of the state of the art and challenges

Large-scale metal additive manufacturing: a holistic review of the state of the art and challenges

Simulation of wire and arc additive manufacturing of 308L stainless steel with cold arc gas metal arc welding

Effect of the Electrode Extension on the Geometry of Parts Made of 316LSi Steel by Wire Arc Additive Manufacturing Method (WAAM)

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