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.
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.
High deposition rate with minimal heat input is one of the primary emphasis in wire arc additive manufacturing. This study aims to determine the optimal input parameters of micro plasma welding for single-layer deposition. The stability of a single layer is crucial as it serves as the foundation to the multi-layers deposition in producing 3D additively manufactured structure. The study focuses on wire feeding speed, welding speed, and pulse and their interaction between the input and response variables. Based on the study, the regression equation between the three key parameters and the response using the Box-Behnken Design response surface methodology was proposed. The outcome demonstrates that the optimized sample deposition produces a smooth surface appearance with no apparent defects. additive manufacturing 3D printing wire arc additive manufacturing micro plasma arc welding response surface methodology
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