Wire and arc additive manufacturing: Opportunities and challenges to control the quality and accuracy of manufactured parts

Jafari, Davoud; Vaneker, Thomas H.J.; Gibson, Ian

doi:10.1016/j.matdes.2021.109471

Cited by 309 publications

(115 citation statements)

References 304 publications

Supporting

Mentioning

113

Contrasting

Unclassified

Order By: Relevance

“…Due to the nature of arc-based deposition processes-high deposition rate and large molten pool-WAAM has been proven as suitable to produce medium to large components with medium complexity. However, the successful and efficient production of parts with specific features by WAAM strongly depends on a cautious process planning, which includes an integrated selection of several and typically interrelated process parameter, such as build setup conditions, deposition parameters, consumables, path planning, thermal management, and post-processing [1].…”

Section: Introductionmentioning

confidence: 99%

Work Envelope Expansion and Parametric Optimization in WAAM with Relative Density and Surface Aspect as Quality Constraints: The Case of Al5Mg Thin Walls with Active Cooling

Silva

Teixeira

Araújo

et al. 2021

JMMP

View full text Add to dashboard Cite

The successful and efficient production of parts with specific features by Wire + Arc Additive Manufacturing (WAAM) strongly depends on the selection of proper and typically interrelated deposition parameters. This task might be particularly challenging in the making of thin walls, which might be highly impacted by processing conditions and heat accumulation. In this context, this study aims at expanding the work envelope and optimizing the parametric conditions in WAAM with relative density and surface aspects of the preforms as quality constraints. The experimental approach was based on the deposition of thin Al5Mg walls by the CMT process on its standard welding setup and with an active cooling technique to enhance the deposition robustness. Internal voids were estimated by Archimedes’ method. The surface quality of the walls was assessed through the visual aspect and the surface waviness by cross-section analysis. All the conditions presented relative density higher than 98%. The upgrade of the standard welding hardware to WAAM purposes through the addition of a supplementary shielding gas nozzle to the torch and the intensity of the heat sinking from the part significantly expanded the process work envelope, with its applicability being successfully demonstrated with multi-objective optimization. To sum up, a decision-making procedure is presented towards achieving intended preform quality.

show abstract

Section: Introductionmentioning

confidence: 99%

Work Envelope Expansion and Parametric Optimization in WAAM with Relative Density and Surface Aspect as Quality Constraints: The Case of Al5Mg Thin Walls with Active Cooling

Silva

Teixeira

Araújo

et al. 2021

JMMP

View full text Add to dashboard Cite

show abstract

“…Welding processes that offer both the high deposition rates of GMAW and manage ment of the thermal energy inputs will allow for more desirable and accurate WAAM deposition conditions whilst maintaining competitive methods for the fabrication of meta structures [6,18]. Two GMAW formats were reviewed in this study to obtain a comparison between conventional GMAW and modified processes, which have a greater degree o control over their deposition conditions:…”

mentioning

confidence: 99%

“…2. GMAW-Cold Metal Transfer (CMT)-a GMAW derived process that utilizes con trolled short circuit transfer and reciprocating wire feeding to minimize heat input and assist in molten droplet transfer from filler material to melt pool [18].…”

mentioning

confidence: 99%

“…The calculated heat input and cooling rate can be used as reference values and can be compared against hardness values to char acterize the formation of the microstructures in the weld metal. Yildiz et al found that fo WAAM-fabricated ER120S-G steel the formation of martensite and bainite was mor prominent in samples produced at low heat inputs (339 J/mm) with the highest proportion of martensite found in single-layer samples producing average hardness values of 400 Welding processes that offer both the high deposition rates of GMAW and management of the thermal energy inputs will allow for more desirable and accurate WAAM deposition conditions whilst maintaining competitive methods for the fabrication of metal structures [6,18]. Two GMAW formats were reviewed in this study to obtain a comparison between conventional GMAW and modified processes, which have a greater degree of control over their deposition conditions:…”

mentioning

confidence: 99%

“…GMAW-MIG-commonly known as "MIG" welding, which uses a metal filler wire as a consumable electrode and continuously feeds from a welding torch which provides a local shielding gas supply to the weld and surrounding component. Material transfer in this process mode can occur in multiple formats; short-circuiting, spray transfer and globular transfer [18].…”

mentioning

confidence: 99%

See 2 more Smart Citations

Comparison of Properties and Bead Geometry in MIG and CMT Single Layer Samples for WAAM Applications

Stinson

Ward

Quinn

et al. 2021

Metals

View full text Add to dashboard Cite

The process of Wire Arc Additive Manufacturing (WAAM) utilizes arc welding technology to fabricate metallic components by depositing material in a selective layered fashion. Several welding processes exist that can achieve this layered deposition strategy. Gas Metal Arc Welding (GMAW) derived processes are commonly favored for their high deposition rates (1–4 kg/h) and minimal torch reorientation required during deposition. A range of GMAW processes are available; all of which have different material transfer modes and thermal energy input ranges and the resultant metallic structures formed from these processes can vary in their mechanical properties and morphology. This work will investigate single-layer deposition and vary the process parameters and process mode to observe responses in mechanical properties, bead geometry and deposition rate. The process modes selected for this study were GMAW derived process of Metal Inert Gas (MIG) and Cold Metal Transfer (CMT). Characterization of parameter sets revealed relationships between torch travel speeds, wire feed speeds and the specimen properties and proportions. Differences were observed in the cross-sectional bead geometry and deposition rates when comparing MIG and CMT samples though the influence of process mode on mechanical properties was less significant compared to process parameter selection.

show abstract

Advanced Techniques in Wire Arc Additive Manufacturing

Sivakumar,

Karthikeyan,

Balaji

et al. 2024

Advances in Additive Manufacturing

View full text Add to dashboard Cite

Wire and arc additive manufacturing: Opportunities and challenges to control the quality and accuracy of manufactured parts

Cited by 309 publications

References 304 publications

Work Envelope Expansion and Parametric Optimization in WAAM with Relative Density and Surface Aspect as Quality Constraints: The Case of Al5Mg Thin Walls with Active Cooling

Work Envelope Expansion and Parametric Optimization in WAAM with Relative Density and Surface Aspect as Quality Constraints: The Case of Al5Mg Thin Walls with Active Cooling

Comparison of Properties and Bead Geometry in MIG and CMT Single Layer Samples for WAAM Applications

Advanced Techniques in Wire Arc Additive Manufacturing

Contact Info

Product

Resources

About