Arc-welding based additive manufacturing for body reinforcement in automotive engineering

Josten, A.; Höfemann, Matthias

doi:10.1007/s40194-020-00959-3

Cited by 14 publications

(10 citation statements)

References 2 publications

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“…AM strengthening has been developed by considering use of wire-and-arc additive manufactured (WAAM) stiffener (Figure 1) on one side of the plate. Similar solutions were explored for stiffening of I-beam web [5] or body reinforcement of automotive engineering [6]. In this paper, different arrangements of WAAM plate stiffeners and comparison to traditional prismatic stiffener are investigated.…”

Section: Introductionmentioning

confidence: 99%

Stiffening of slender plates using Wire Arc Additive Manufacturing

Tankova,

Veljkovic

2023

ce papers

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Additive manufacturing provides the possibility for innovative structural configurations promoting optimized material use for economy and sustainability, and new functions which are not available for traditional products. This paper explores the possibility to use wire‐and‐arc directed energy deposition process for fabrication of innovative WAAM stiffener for thin plated structures. The proposed solution is demonstrated in several geometrical configurations by varying depth and thickness of stiffener, by including openings or not, in addition to adopting irregular shapes such as circular of ellipsoidal stiffeners. The performance of the WAAM stiffened panel is compared to use of thin plate stiffened by prismatic stiffener by considering the critical buckling load and resistance for three different load cases. The results from the analyses performed showed that the WAAM stiffened panels reach the same resistance as the traditionally stiffened plate but using less material.

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Section: Introductionmentioning

confidence: 99%

Stiffening of slender plates using Wire Arc Additive Manufacturing

Tankova,

Veljkovic

2023

ce papers

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“…Furthermore, additional stiffening structures produced by WAAM can adapt sheets or profiles specifically to certain applications. Josten and Höfemann [5] demonstrated that single-layer grids on flat car body sheets could increase the bending stiffness by 50-90%.…”

Section: Introductionmentioning

confidence: 99%

Characterisation of structural modifications on cold-formed AA2024 substrates by wire arc additive manufacturing

Silmbroth

Enzinger

Schneider-Bröskamp

et al. 2023

Science and Technology of Welding and Joining

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Wire arc additive manufacturing, employing conventional fusion welding processes, shows excellent versatility and can therefore be used for structural modifications of existing parts to create hybrid components. This study evaluates the modification of cold-formed AA2024 metal sheets with 2xxx filler metals to produce 2xxx hybrid structures. The alloys are investigated by thermodynamic simulations and the solidification crack susceptibility is assessed by calculating the index for hot cracking susceptibility. Using cold metal transfer, single-layer depositions are generated on profile sheets after which the specimens are characterised by three analysis procedures: metallographic analysis, chemical analysis, and hardness testing. Results indicate that AA2024 wire material, although generally considered difficult to weld, is more suitable for the additive modification of AA2024 sheets and profiles, as crack-free specimens can be deposited on cold-formed substrates.

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“…In the industry, this example from everyday life is often met when welding [1-3], screwing, or joining two flexible parts: if the operations of fixation are not executed in a well designed order, these parts may not be well assembled considering the project requirements. Additive manufacturing of stiffeners on metal sheets produces the same kind of issues [4,5]. It generates some deflections on these parts.…”

Section: Introductionmentioning

confidence: 99%

Learning the Parametric Transfer Function of Unitary Operations for Real-Time Evaluation of Manufacturing Processes Involving Operations Sequencing

et al. 2021

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For better designing manufacturing processes, surrogate models were widely considered in the past, where the effect of different material and process parameters was considered from the use of a parametric solution. The last contains the solution of the model describing the system under study, for any choice of the selected parameters. These surrogate models, also known as meta-models, virtual charts or computational vademecum, in the context of model order reduction, were successfully employed in a variety of industrial applications. However, they remain confronted to a major difficulty when the number of parameters grows exponentially. Thus, processes involving trajectories or sequencing entail a combinatorial exposition (curse of dimensionality) not only due to the number of possible combinations, but due to the number of parameters needed to describe the process. The present paper proposes a promising route for circumventing, or at least alleviating that difficulty. The proposed technique consists of a parametric transfer function that, as soon as it is learned, allows for, from a given state, inferring the new state after the application of a unitary operation, defined as a step in the sequenced process. Thus, any sequencing can be evaluated almost in real time by chaining that unitary transfer function, whose output becomes the input of the next operation. The benefits and potential of such a technique are illustrated on a problem of industrial relevance, the one concerning the induced deformation on a structural part when printing on it a series of stiffeners.

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Arc-welding based additive manufacturing for body reinforcement in automotive engineering

Cited by 14 publications

References 2 publications

Stiffening of slender plates using Wire Arc Additive Manufacturing

Stiffening of slender plates using Wire Arc Additive Manufacturing

Characterisation of structural modifications on cold-formed AA2024 substrates by wire arc additive manufacturing

Learning the Parametric Transfer Function of Unitary Operations for Real-Time Evaluation of Manufacturing Processes Involving Operations Sequencing

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