Towards Wire and Arc Additive Manufacturing of High-Quality Parts

Baier, Daniel; Bachmann, Andreas; Zaeh, Michael F.

doi:10.1016/j.procir.2020.01.180

Cited by 13 publications

(3 citation statements)

References 8 publications

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“…The CSG method helps to reduce the complexity of parts by defining smaller and different-sized volume primitives. These volume primitives must be manufactured first to generate the fundamental process understanding and achieve high-quality parts [4]. However, the high quality requirements posed in aerospace have made the transition to the industrial production process challenging [2].…”

Section: Introductionmentioning

confidence: 99%

Approach towards a Quality Assurance System for Wire and Arc Additive Manufacturing

et al. 2023

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Wire and Arc Additive Manufacturing (WAAM) of Ti-6Al-4V is becoming increasingly important in the aerospace industry for the production of large parts. Due to the high welding requirements of the material, high quality demands are placed on the process. To meet these high demands, quality assurance measures are applied to maintain mechanical and geometrical part properties. First, the interlayer temperatures that are applied influence the final geometry. The part must meet geometric accuracies in order to be machined after the WAAM process. Second, Ti-6Al-4V materials have a high affinity to absorb oxygen from the environment at elevated temperatures. This oxygen uptake results in a discoloration of the surface and an embrittlement of the material. Therefore, a defined and monitored oxygen content in the build chamber is crucial. This work presents an approach to determine limitations for the interlayer temperature of the part and the oxygen content in the build chamber. The influence of a temperature deviating from the set interlayer temperature on the layer width was analyzed. By varying the interlayer temperature, the layer width varied by up to 3 mm. It was shown that different restrictions for the oxygen content in the build chamber apply depending on the part size.

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Section: Introductionmentioning

confidence: 99%

Approach towards a Quality Assurance System for Wire and Arc Additive Manufacturing

et al. 2023

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“…Near‐net‐shape production of these structural components is a promising approach to solve this problem. [ 12–19 ] Many of the standard additive manufacturing processes, e.g., laser powder bed fusion or electron beam melting, allow the fabrication of more complex structures due to the powder feedstock and a small diameter of heat input. [ 20–22 ] However, these techniques have slow build‐up rates and are often also restricted to smaller part sizes, which make these techniques inefficient for the need of serial production for larger aviation parts.…”

Section: Introductionmentioning

confidence: 99%

Development of Microstructure and Mechanical Properties of TiAl6V4 Processed by Wire and Arc Additive Manufacturing

et al. 2022

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Wire and arc additive manufacturing (WAAM) has the potential to significantly reduce material waste due to the milling of components made of TiAl6V4 (Ti‐64). To keep up with the market development, this resource‐efficient technology is becoming increasingly important to achieve climate policy goals. Therefore, this study not only focuses on the influence of different process parameters, such as torch and wire feed speed, but also different gas mixtures on the microstructure and related mechanical properties, as well as on the scalability by investigating single‐ to multilayer welded structures. The wire feed speed is found to have a major influence on the geometry and mechanical properties. The use of different process gases, i.e., argon (Ar), helium (He), and a mixture of 70% He and 30% Ar neither significantly affect the microstructure nor the mechanical properties. It is also found that a solution heat treatment followed by an annealing step degrades mechanical properties, while an ordinary stress‐relief heat treatment leads to improved mechanical properties. It is shown that by adapting WAAM process and heat treatment parameters, mechanical properties of additively produced specimens can be achieved, which are fully comparable to milled components.

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“…To achieve the climate targets set by the European Commission, formulated in the The European Green Deal in 2019 [1], modern production processes must continuously become more energy and resource-efficient. In the aerospace industry especially, where the production of large structural components is resource-intensive, additive manufacturing processes promise high resource efficiency [2]. Nevertheless, post-processing of the workpieces, for example by milling, is still required to achieve high geometrical accuracy [3].…”

Section: Introductionmentioning

confidence: 99%

Multi-Fidelity Information Fusion to Model the Position-Dependent Modal Properties of Milling Robots

Busch

Zaeh

2022

Robotics

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Robotic machining is a promising technology for post-processing large additively manufactured parts. However, the applicability and efficiency of robot-based machining processes are restricted by dynamic instabilities (e.g., due to external excitation or regenerative chatter). To prevent such instabilities, the pose-dependent structural dynamics of the robot must be accurately modeled. To do so, a novel data-driven information fusion approach is proposed: the spatial behavior of the robot’s modal parameters is modeled in a horizontal plane using probabilistic machine learning techniques. A probabilistic formulation allows an estimation of the model uncertainties as well, which increases the model reliability and robustness. To increase the predictive performance, an information fusion scheme is leveraged: information from a rigid body model of the fundamental behavior of the robot’s structural dynamics is fused with a limited number of estimated modal properties from experimental modal analysis. The results indicate that such an approach enables a user-friendly and efficient modeling method and provides reliable predictions of the directional robot dynamics within a large modeling domain.

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Towards Wire and Arc Additive Manufacturing of High-Quality Parts

Cited by 13 publications

References 8 publications

Approach towards a Quality Assurance System for Wire and Arc Additive Manufacturing

Approach towards a Quality Assurance System for Wire and Arc Additive Manufacturing

Development of Microstructure and Mechanical Properties of TiAl6V4 Processed by Wire and Arc Additive Manufacturing

Multi-Fidelity Information Fusion to Model the Position-Dependent Modal Properties of Milling Robots

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