Design and Parameter Identification of Wire and Arc Additively Manufactured (WAAM) Steel Bars for Use in Construction

Müller, Johanna; Grabowski, Marcel; Müller, Christoph; Hensel, Jonas; Unglaub, Julian; Thiele, Klaus; Kloft, Harald; Dilger, Klaus

doi:10.3390/met9070725

Cited by 95 publications

(42 citation statements)

References 32 publications

(29 reference statements)

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“…Thereby, wire arc additive manufacturing (WAAM) of steel parts is mainly addressed. Recent investigations on low-alloyed steel [13][14][15][16] or high-alloyed steel [17,18] demonstrate the potential for these sectors.…”

Section: Introduction and State Of The Artmentioning

confidence: 99%

Reduction of Energy Input in Wire Arc Additive Manufacturing (WAAM) with Gas Metal Arc Welding (GMAW)

et al. 2020

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Wire arc additive manufacturing (WAAM) by gas metal arc welding (GMAW) is a suitable option for the production of large volume metal parts. The main challenge is the high and periodic heat input of the arc on the generated layers, which directly affects geometrical features of the layers such as height and width as well as metallurgical properties such as grain size, solidification or material hardness. Therefore, processing with reduced energy input is necessary. This can be implemented with short arc welding regimes and respectively energy reduced welding processes. A highly efficient strategy for further energy reduction is the adjustment of contact tube to work piece distance (CTWD) during the welding process. Based on the current controlled GMAW process an increase of CTWD leads to a reduction of the welding current due to increased resistivity in the extended electrode and constant voltage of the power source. This study shows the results of systematically adjusted CTWD during WAAM of low-alloyed steel. Thereby, an energy reduction of up to 40% could be implemented leading to an adaptation of geometrical and microstructural features of additively manufactured work pieces.

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Section: Introduction and State Of The Artmentioning

confidence: 99%

Reduction of Energy Input in Wire Arc Additive Manufacturing (WAAM) with Gas Metal Arc Welding (GMAW)

et al. 2020

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“…Researchers have studied different techniques for the process, including conventional gas tungsten arc welding (GTAW), gas metal arc welding (GMAW), and cold metal transfer (CMT) [6,7]. This includes studies on topology, build-up geometry, and material properties of structures made by these methods [8,9]. Comprehensive studies have been conducted on defects in microstructure and methods to improve them by controlling deposition strategies and incorporating ancillary processes for quality enhancement [10][11][12].…”

Section: Introductionmentioning

confidence: 99%

Analysis of Ductile Fracture Obtained by Charpy Impact Test of a Steel Structure Created by Robot-Assisted GMAW-Based Additive Manufacturing

Waqas

Qin

Xiong

et al. 2019

Metals

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In this study, gas metal arc welding (GMAW) was used to construct a thin wall structure in a layer-by-layer fashion using an AWS ER70S-6 electrode wire with the help of a robot. The Charpy impact test was performed after extracting samples in directions both parallel and perpendicular to the deposition direction. In this study, multiple factors related to the resulting absorbed energy have been discussed. Despite being a layered structure, homogeneous behavior with acceptable deviation was observed in the microstructure, hardness, and fracture toughness of the structure in both directions. The fracture is extremely ductile with a dimpled fibrous surface and secondary cracks. An estimate for fracture toughness based on Charpy impact absorbed energy is also given.

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“…The manufacturer of the welding material gives the yield strength as at least 420 N/mm 2 . This slight undercutting of the tensile test specimens is common in Additive Manufacturing, see [16]. The strengths are usually higher in tensile specimens that are loaded longitudinally to the course of the layers, so the unfavourable direction was assessed here.…”

Section: Articlementioning

confidence: 99%

3D printing with steel

2020

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Extended keynote paper of Eurosteel 2021 Automated production is finding its way into the fabrication of structural steel. One robot holds attachments (stiffeners, end plates, etc.) on a steel beam or column and another robot produces weld seams. However, welding robots can also be used for Additive Manufacturing (Wire and Arc Additive Manufacturing, WAAM). The wire electrode serves as a printing material. The Institute of Steel Construction and Materials Mechanics in Darmstadt is investigating how typical connecting elements for steel structures can be printed directly on steel beams using Additive Manufacturing with arc welding and robots. Furthermore, structural elements such as nodes for space frames can be printed and even complete structures, e.g. columns and a little bridge, have already been manufactured additively. The main focus is on determining suitable welding and process parameters. In addition, topology optimization is necessary in order to achieve good structures using a small amount of material. This is possible due to the free design prospects of WAAM, which opens up new design and production strategies.

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Design and Parameter Identification of Wire and Arc Additively Manufactured (WAAM) Steel Bars for Use in Construction

Cited by 95 publications

References 32 publications

Reduction of Energy Input in Wire Arc Additive Manufacturing (WAAM) with Gas Metal Arc Welding (GMAW)

Reduction of Energy Input in Wire Arc Additive Manufacturing (WAAM) with Gas Metal Arc Welding (GMAW)

Analysis of Ductile Fracture Obtained by Charpy Impact Test of a Steel Structure Created by Robot-Assisted GMAW-Based Additive Manufacturing

3D printing with steel

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