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.
This paper presents the comparative study of design efficiency of two different brands of products, performing the same function using the Design for Manufacturing and Assembly (DFMA) method. The study aims to compare the products on the relative design efficiency. The DFMA method was used as it is a well-established technique for improving the efficiency of the product leading to minimizing production costs. It also shortens product development time by reducing the number of components in a product. The study used two different brands of dry iron as a case study. The result shows that the percentage of the design efficiency of dry iron A is 8.82%, whereas it is 10.34% of dry iron B. Thus, the dry iron B is much better as compared to A in term of its assembly operation and design efficiency. Therefore, the dry iron B is greener than dry iron A. Furthermore, a redesign of dry iron B was proposed and analyzed for the internal validation. The DFMA analysis result shows that the percentage of design efficiency of a new conceptual design of dry iron B increased to 18.08%. The application of the DFMA method to enhance the eco-friendliness of a product has been proven to be highly useful in design work.
Wire and arc additive manufacturing (WAAM) has developed a wide range of processes and applications. This technology is a new approach to modern manufacturing and is gaining interest from the research community due to its ability to create affordable, large-scale components. Nevertheless, WAAM may affected by porosity, humping and undercut. These issues need to be addressed in a specific way to achieve desired quality that is comparable to the traditional processing technique. This article examines various weld travel speeds, where defects start appearing. The effects of travel speed and wire feed speed (WFS) were also discussed. It was found that, travel speed and WFS had a major influence on deposition width and height and a stable deposited layer was produced between heat input values of 0.2620 kJ/mm and 0.32756 kJ/mm.
scite is a Brooklyn-based organization that helps researchers better discover and understand research articles through Smart Citations–citations that display the context of the citation and describe whether the article provides supporting or contrasting evidence. scite is used by students and researchers from around the world and is funded in part by the National Science Foundation and the National Institute on Drug Abuse of the National Institutes of Health.