No abstract

Wire arc additive manufacturing (WAAM) is a crucial technique in the fabrication of 3D metallic structures. It is increasingly being used worldwide to reduce costs and time. Generally, AM technology is used to overcome the limitations of traditional subtractive manufacturing (SM) for fabricating large-scale components with lower buy-to-fly ratios. There are three heat sources commonly used in WAAM: metal inert gas welding (MIG), tungsten inert gas welding (TIG), and plasma arc welding (PAW). MIG is easier and more convenient than TIG and PAW because it uses a continuous wire spool with the welding torch. Unlike MIG, tungsten inert gas welding (TIG) and plasma arc welding (PAW) need an external wire feed machine to supply the additive materials. WAAM is gaining popularity in the fabrication of 3D metal components, but the process is hard to control due to its inherent residual stress and distortion, which are generated by the high thermal input from its heat sources. Distortion and residual stress are always a challenge for WAAM because they can affect the component’s geometric accuracy and drastically degrade the mechanical properties of the components. In this paper, wire-based and wire arc technology processes for 3D metal printing, including their advantages and limitations are reviewed. The optimization parametric study and modification of WAAM to reduce both residual stress and distortion are tabulated, summarized, and discussed.

No abstract

Purpose This study aims is to investigate the correlation between tribological and mechanical properties of the fused filament fabrication 3D-printed acrylonitrile butadiene styrene (ABS) pin with different internal geometries. Design/methodology/approach The tribological properties were determined by a dry sliding test with constant test parameters, while the hardness and modulus of elasticity were determined by microhardness and compression tests. Findings Although the internal geometry of the pin sample slightly affects the coefficient of friction (COF) and the wear rate of the 3D-printed ABS, it was important to design a lightweight tribo-component by reducing the material used to save energy without compromising the strength of the component. The COF and wear rate values are relatively dependent on the elastic modulus. A 3D-printed ABS pin with an internal triangular flip structure was found to have the shortest run-in period and the lowest COF with high wear resistance. Abrasive wear and delamination are the predominant wear mechanisms involved. Research limitations/implications The findings are the subject of future research under various sliding conditions by investigating the synergistic effect of sliding speeds and applied loads to validate the results of this study. Originality/value The internal structure affects the mechanical properties and release stress concentration at the contact point, resulting in hypothetically low friction and wear. This approach may also reduce the weight of the parts without scarifying or at least preserving their preceding tribological performance. Therefore, based on our knowledge, limited studies have been conducted for the application of 3D printing in tribology, and most studies focused on improving their mechanical properties rather than correlating them with tribological properties that would benefit longer product lifespans. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-04-2020-0143/

This study intends to analyse the coefficient of friction and wear properties of the acrylonitrile butadiene styrene polymer by determining the optimal parameters for 3D printing. The pin specimens were produced using the fused filament fabrication 3D printing. Response surface methodology is used for the multivariate analysis, and Box–Behnken Design is the chosen symmetrical design method. Changes to the dependent variables, coefficient of friction and wear rate, were analysed as a function of the nozzle temperature, layer height and printing pattern. The coefficient of friction and wear rate were measured using a pin-on-disc tribometer. A good agreement between the modelled and measured values of coefficient of friction and wear rate was observed. The study suggests that layer height affecting coefficient of friction and wear rate most significantly. It is determined that a layer height of 0.10 mm and a nozzle temperature of 234℃ using the triangle printing pattern is the optimal set of combination to minimise coefficient of friction and wear rate.