Cost Modelling and Sensitivity Analysis of Wire and Arc Additive Manufacturing

Cunningham, Chloe; Wikshåland, S.; Xu, Fujun; Kemakolam, N.; Shokrani, Alborz; Dhokia, Vimal; Newman, Stephen T.

doi:10.1016/j.promfg.2017.07.163

Cited by 93 publications

(50 citation statements)

References 9 publications

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“…It is essential to understand the performance of the AM processes cost-effectiveness for an efficient extension of AM. Both knowledge of process capabilities and operative cost modeling can show a helpful vision into the potential cost increase or "real cost" of a special AM process [141]. There are two main ways for evaluating AM costs.…”

Section: Economic Impacts Of Ammentioning

confidence: 99%

The Potential of Additive Manufacturing in the Smart Factory Industrial 4.0: A Review

et al. 2019

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Additive manufacturing (AM) or three-dimensional (3D) printing has introduced a novel production method in design, manufacturing, and distribution to end-users. This technology has provided great freedom in design for creating complex components, highly customizable products, and efficient waste minimization. The last industrial revolution, namely industry 4.0, employs the integration of smart manufacturing systems and developed information technologies. Accordingly, AM plays a principal role in industry 4.0 thanks to numerous benefits, such as time and material saving, rapid prototyping, high efficiency, and decentralized production methods. This review paper is to organize a comprehensive study on AM technology and present the latest achievements and industrial applications. Besides that, this paper investigates the sustainability dimensions of the AM process and the added values in economic, social, and environment sections. Finally, the paper concludes by pointing out the future trend of AM in technology, applications, and materials aspects that have the potential to come up with new ideas for the future of AM explorations.

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Section: Economic Impacts Of Ammentioning

confidence: 99%

The Potential of Additive Manufacturing in the Smart Factory Industrial 4.0: A Review

et al. 2019

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“…Compared with powder laser additive manufacturing, wire and arc additive manufacturing (WAAM) can reduce raw material wastage and has advantages of high molding efficiency, low cost, and easy commercialization [1,2]. For example, plasma arc additive manufacturing has been employed by Jhavar et al [3] to produce AISI P20 steel samples exhibiting no cracks, pores, or inclusions on the micro level.…”

Section: Introductionmentioning

confidence: 99%

Forming Process, Microstructure, and Mechanical Properties of Thin-Walled 316L Stainless Steel Using Speed-Cold-Welding Additive Manufacturing

Xue

Wang

et al. 2019

Metals

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Wire and arc additive manufacturing (WAAM) produces thin-walled parts superior to other additive manufacturing methods, because of its high efficiency, good compactability, and low cost. However, the WAAM accuracy is limited by its large heat input. Here, 0.8 mm 316L stainless steel welding wire is deposited via speed cold welding to form 30-layered thin-walled samples, with 2 mm thickness, and up to 65 mm height. The effects of three process parameters (the bottom current mode, scanning speed, and cooling time) on the deposition process stability, macro morphology, structure, and mechanical properties are studied. In the experiment, the probability density curves of electrical parameters of sample #GRBC-30 cm/min-10 s on the third and tenth layers were narrower than other samples, which implied a more stable process. The three process parameters mainly affect the deposition morphology and have a minor performance effect. The hardness and tensile properties mainly depend on the deposition direction. Gradual, layer-by-layer current reduction improves the bottom molding and performance, and the deposition efficiency, and stabilizes the process. Scanning speed enhancement or cooling time reduction destabilizes the end formation, reduces the effective deposition rate, and slightly degrades the performance. All deposited samples are distinctly anisotropic, but satisfy the industrial standard. Overall, deposition in speed cold welding mode, with 10 s cooling time, 30 cm/min scanning speed, and gradually reduced bottom current exhibits good stability, and the molding efficiency and mechanical properties are optimal.

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“…In this process, a metal wire serves as raw material, with relatively reduced energy consumption being required to fuse the wire into a pre-designed metal component. The WAAM process usually uses widely used welding technologies, such as gas metal arc welding (GMAW) that can reduce the production cost in terms of raw material and energy consumption by nearly 80%, as compared to the PBT process [9,10]. In practice, WAAM can provide a deposition rate of about 10 kg/h [11], as compared to a rate of only 600 g/h achieved by the conventional PBT process [12].…”

Section: Introductionmentioning

confidence: 99%

Environmental Behavior of Low Carbon Steel Produced by a Wire Arc Additive Manufacturing Process

Ron

Levy

Dolev

et al. 2019

Metals

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: Current additive manufacturing (AM) processes are mainly focused on powder bed technologies, such as electron beam melting (EBM) and selective laser melting (SLM). However, the main disadvantages of such techniques are related to the high cost of metal powder, the degree of energy consumption, and the sizes of the components, that are limited by the size of the printing cell. The aim of the present study was to evaluate the environmental behavior of low carbon steel (ER70S-6) produced by a relatively inexpensive AM process using wire feed arc welding. The mechanical properties were examined by tension testing and hardness measurements, while microstructure was assessed by scanning electron microscopy and X-ray diffraction analysis. General corrosion performance was evaluated by salt spray testing, immersion testing, potentiodynamic polarization analysis, and electrochemical impedance spectroscopy. Stress corrosion performance was characterized in terms of slow strain rate testing (SSRT). All corrosion tests were carried out in 3.5% NaCl solution at room temperature. The results indicated that the general corrosion resistance of wire arc additive manufacturing (WAAM) samples were quite similar to those of the counterpart ST-37 steel and the stress corrosion resistance of both alloys was adequate. Altogether, it was clearly evident that the WAAM process did not encounter any deterioration in corrosion performance compared to its conventional wrought alloy counterpart.

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Cost Modelling and Sensitivity Analysis of Wire and Arc Additive Manufacturing

Cited by 93 publications

References 9 publications

The Potential of Additive Manufacturing in the Smart Factory Industrial 4.0: A Review

The Potential of Additive Manufacturing in the Smart Factory Industrial 4.0: A Review

Forming Process, Microstructure, and Mechanical Properties of Thin-Walled 316L Stainless Steel Using Speed-Cold-Welding Additive Manufacturing

Environmental Behavior of Low Carbon Steel Produced by a Wire Arc Additive Manufacturing Process

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