Wire and arc additive manufacturing of metal components: a review of recent research developments

Liu, Jienan; Xu, Yanling; Yu, Ge; Hou, Zhengxin; Chen, Shanben

doi:10.1007/s00170-020-05966-8

Cited by 119 publications

(35 citation statements)

References 101 publications

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“…In recent times, research activity in WAAM has increased rapidly and developed systems to dynamically control the deposited bead geometry is one of key focal areas (Liu et al, 2020). In a conventional WAAM setup, welding parameters that control deposition rates for a particular layer are preprogrammed.…”

Section: Introductionmentioning

confidence: 99%

Layer-by-layer model-based adaptive control for wire arc additive manufacturing of thin-wall structures

Polden

et al. 2022

J Intell Manuf

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Improving the geometric accuracy of the deposited component is essential for the wider adoption of wire arc additive manufacturing (WAAM) in industries. This paper introduces an online layer-by-layer controller that operates robustly under various welding conditions to improve the deposition accuracy of the WAAM process. Two control strategies are proposed and evaluated in this work: A PID algorithm and a multi-input multi-output model-predictive control (MPC) algorithm. After each layer of deposition, the deposited geometry is measured using a laser scanner. These measurements are compared against the CAD model, and geometric errors are then compensated by the controller, which generates a new set of welding parameters for the next layer. The MPC algorithm, combined with a linear autoregressive (ARX) modelling process, updates welding parameters between successive layers by minimizing a cost function based on sequences of input variables and predicted responses. Weighting coefficients of the ARX model are trained iteratively throughout the manufacturing process. The performance of the designed control architecture is investigated through both simulation and experiments. Results show that the real-time control performance is improved by increasing the complexity of implemented control algorithm: controlled geometric fluctuations in the test component were reduced by 200% whilst maintaining fluctuations within a 3 mm limit under various welding conditions. In addition, the adaptiveness of designed control strategy is verified by accurately controlling the fabrication of a part with complex geometry.

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Section: Introductionmentioning

confidence: 99%

Layer-by-layer model-based adaptive control for wire arc additive manufacturing of thin-wall structures

Polden

et al. 2022

J Intell Manuf

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“…The bed deposition technology is effectively used for the fabrication of small NiTi parts while the direct deposition technology is convenient for the production of massive elements [4]. One of the direct deposition technology is the wire arc additive manufacturing (WAAM) [5][6] which now is used for the production of NiTi samples including walls and 3D structures [7][8][9][10][11]. Previously, it was found that the structure of the NiTi samples produced by WAAM depended on the substrate materials, arc voltage, arc current and pre-heating temperature of substrate [12][13][14].…”

Section: Introductionmentioning

confidence: 99%

Influence of annealing on the functional properties of the NiTi alloy produced by wire arc additive manufacturing

Resnina

Palani

Belyaev

et al. 2022

IOP Conf. Ser.: Mater. Sci. Eng.

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The influence of the annealing temperature on the recoverable strain variation on cooling and heating under a stress of 200 MPa was studied in the NiTi samples produced by wire arc additive manufacturing. The samples including the Ni-rich NiTi layer in the working length were annealed for 10 hours at various temperature from 450 to 600 °C. It is shown that an increase in annealing temperature leads to non-monontonic variation in the recoverable strain. This is caused by an increase in annealing temperature from 450 to 550 °C increases the volume fraction of Ni4Ti3 precipitates. As a result, the volume fraction of the NiTi phase undergoing the martensitic transformation and recoverable strain decrease. An increase in annealing temperature from 550 to 600 °C leads to a dissolving the Ni4Ti3 precipitates and formation of the Ni3Ti2 precipitates that increases the volume fraction of the NiTi phase and the recoverable strain.

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“…Wire feedstock makes WAAM process cost-effective and environment friendly as well as high material utilizing [6]. Compared with other AM technologies, WAAM is identified by significantly great deposition rate (3-10 kg/h), unlimited building envelope, and low capital cost [7]. All these characteristics make WAAM suitable to fabricate fully dense near-net-shaped metallic components for building applications with high forming efficiency at a low investment [8] and maximize the design freedom [9].…”

Section: Introductionmentioning

confidence: 99%

800 MPa Class HSLA Steel Block Part Fabricated by WAAM for Building Applications: Tensile Properties at Ambient and Elevated (600°C) Temperature

Fang

Zhao

Chen

et al. 2022

Advances in Materials Science and Engineering

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An 800 MPa class high strength low-alloy (HSLA) steel block part was deposited on substrate with similar composition by gas metal arc welding (GMAW)-based wire arc additive manufacturing (WAAM). The base plate could be removed after deposition or retained as part of the additive manufacturing (AM) part, forming the hybrid additive manufacturing (HAM) part. Tensile tests of the AM part and the HAM part were performed at ambient temperature (AT) and elevated temperature (ET, 600°C held for 4 h) for potential applications in high-rise buildings. Microstructure observations and low temperature impact tests were also conducted. Results show that microstructure of the deposit mainly consists of lower bainite and granular bainite. AT yield strength (YS) of the deposit along the deposition, transverse, and vertical directions is ∼770 MPa. ET YS of the deposit along the lateral and building directions could reach 373 MPa, 48.4% of the AT YS. Fracture elongation along all directions could exceed 18.0% for both AT and ET. Low temperature (−50°C) impact absorbed energy of the deposit could exceed 84 J along all directions. Mechanical properties of the HAM part are similar or superior to those of the AM part along the vertical direction, except the AT fracture elongation, which is one-fifth lower. Good strength-ductility-toughness balance of the made part verified the feasibility of using WAAM to manufacture 800 MPa HSLA steel block parts that have potential applications in high-rise buildings, especially considering ET YS of the part might be improved by alloying redesign to meet the performance requirements of building steel.

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Wire and arc additive manufacturing of metal components: a review of recent research developments

Cited by 119 publications

References 101 publications

Layer-by-layer model-based adaptive control for wire arc additive manufacturing of thin-wall structures

Layer-by-layer model-based adaptive control for wire arc additive manufacturing of thin-wall structures

Influence of annealing on the functional properties of the NiTi alloy produced by wire arc additive manufacturing

800 MPa Class HSLA Steel Block Part Fabricated by WAAM for Building Applications: Tensile Properties at Ambient and Elevated (600°C) Temperature

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