Forming optimization for WAAM with weaving deposition on curved surfaces

Ni, Mao; Zhou, Yan; Hu, Zeqi; Qin, Xunpeng; Xiong, Xiaochen; Ji, Feilong

doi:10.1016/j.ijmecsci.2023.108366

Cited by 12 publications

(4 citation statements)

References 75 publications

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“…However, it may incur longer build times, particularly for large and complex components, as it follows a sequential layering process. On the other hand, the oscillating deposition strategy aims to achieve faster build times by covering larger areas in each layer and distributing heat more evenly, potentially reducing thermal distortion [35][36][37]. This approach may sacrifice some surface quality in The mono-seam deposition strategy in Wire Arc Additive Manufacturing (WAAM) offers precision and control over the welding path, leading to accurate layer-by-layer buildup and a potentially smoother surface finish.…”

Section: Geometry Redesign and Contribution Strategymentioning

confidence: 99%

Benefits of Aeronautical Preform Manufacturing through Arc-Directed Energy Deposition Manufacturing

Suárez,

Ramiro,

Veiga

et al. 2023

Materials

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The paper introduces an innovative aerospace component production approach employing Wire Arc Additive Manufacturing (WAAM) technology to fabricate near-finished preforms from Ti6Al4V titanium. Tensile tests on WAAM Ti6Al4V workpieces demonstrated reliable mechanical properties, albeit with identified anisotropic behavior in horizontal samples, underscoring the need for optimization. This alternative manufacturing strategy addresses the challenges associated with machining forged preforms, marked by a high Buy To Fly (BTF) ratio (>10), leading to material wastage, prolonged machining durations, elevated tool expenses, and heightened waste and energy consumption. Additionally, logistical and storage costs are increased due to extended delivery timelines, exacerbated by supply issues related to the current unstable situation. The utilization of WAAM significantly mitigates initial BTF, preform costs, waste production, machining durations, and associated expenditures, while notably reducing lead times from months to mere hours. The novelty in this study lies in the application of Wire Arc Additive Manufacturing (WAAM) technology for the fabrication of titanium aircraft components. This approach includes a unique height compensation strategy and the implementation of various deposition strategies, such as single-seam, overlapping, and oscillating.

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Section: Geometry Redesign and Contribution Strategymentioning

confidence: 99%

Benefits of Aeronautical Preform Manufacturing through Arc-Directed Energy Deposition Manufacturing

Suárez,

Ramiro,

Veiga

et al. 2023

Materials

View full text Add to dashboard Cite

show abstract

“…Derekar et al [14] investigated the effects of different interlayer temperatures on the porosity, and the results showed that the specimens at higher interlayer temperatures had a lower porosity. At present, the acquisition of optimized process parameters usually relies on experiments [15][16][17] or numerical calculations [18,19], which are costly. In addition, most studies do not consider variations of optimal process parameters with different size parameters.…”

Section: Introductionmentioning

confidence: 99%

Study on the Process Window in Wire Arc Additive Manufacturing of a High Relative Density Aluminum Alloy

Wu,

Li,

Wang

et al. 2024

Metals

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In recent years, there has been a heightened focus on multiplex porosity due to its significant adverse impact on the mechanical properties of aluminum alloy components produced through wire arc additive manufacturing (WAAM). This study investigates the impacts of the process parameters and dimension parameters on the relative densities of WAAM 2219 aluminum alloy components by conducting experiments and investigates the changes in high relative density process windows with different dimension parameters. The findings reveal a hierarchy in the influence of various parameters on the relative density of the 2219 aluminum alloy: travel speed (TS), wire feed speed (WFS), the number of printed layers (L), interlayer cooling time (ICT), and theoretical length of weld (TLW). A series of data for analysis was produced through a designed experiment procedure, and on the basis of this, by integrating the data augmentation method with the eXtreme Gradient Boosting (XGBoost) algorithm, the relationship among the process parameters, dimension parameters, and relative density was modeled. Furthermore, through leveraging the established model, we analyzed the changes in the optimized process window corresponding to a high relative density with the L. The optimal windows of WFS and TS change when the L reaches a certain value. In contrast, the optimal window of ICT remains consistent despite an increase in the L. Finally, the relative density and mechanical properties of the formed 20-layer specimens within the model-derived window were verified. The relative density of the specimens within the window reached 98.77%, the ultimate tensile strength (UTS) reached 279.96 MPa, and the yield strength (YS) reached 132.77 MPa. This work offers valuable insights for exploring the process window and selecting process parameters through a more economical and faster approach in WAAM aluminum components.

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“…In particular, using larger weaving amplitudes in combination with a low torch speed and low wavelength allows for the production of walls of larger dimensions [23]. A novel approach to weaving was developed by Ni et al [24] for WAAM on curved surfaces that allowed for the improvement of their dimensional accuracy. It was also shown [25] that plasma torch weaving had a positive effect on the structure and strength of reheated zones in the multi-pass plasma-transferred arc Fe-Cr-Mo-C coatings.…”

Section: Introductionmentioning

confidence: 99%

Effect of “ColdArc” WAAM Regime and Arc Torch Weaving on Microstructure and Properties of As-Built and Subtransus Quenched Ti-6Al-4V

Zykova,

Savchenko,

Nikolaeva

et al. 2024

Materials

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Defect-free thin-walled samples were built using wire arc additive manufacturing (WAAM) combined with the “coldArc” deposition technique by feeding a Ti-6Al-4V welding wire and using two deposition strategies, namely with and without the welding torch weaving. The microstructures formed in these samples were examined in relation to mechanical characteristics. The arc torch weaving at 1 Hz allowed us to interfere with the epitaxial growth of the β-Ti columnar grains and, thus, obtain them a lower aspect ratio. Upon cooling, the α/α′+β structure was formed inside the former β-Ti grains, and this structure proved to be more uniform as compared to that of the samples built without the weaving. The subtransus quenching of the samples in water did not have any effect on the structure and properties of samples built with the arc torch weaving, whereas a more uniform grain structure was formed in the sample built without weaving. Quenching resulted also in a reduction in the relative elongation by 30% in both cases.

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Forming optimization for WAAM with weaving deposition on curved surfaces

Cited by 12 publications

References 75 publications

Benefits of Aeronautical Preform Manufacturing through Arc-Directed Energy Deposition Manufacturing

Benefits of Aeronautical Preform Manufacturing through Arc-Directed Energy Deposition Manufacturing

Study on the Process Window in Wire Arc Additive Manufacturing of a High Relative Density Aluminum Alloy

Effect of “ColdArc” WAAM Regime and Arc Torch Weaving on Microstructure and Properties of As-Built and Subtransus Quenched Ti-6Al-4V

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