Invited review article: Strategies and processes for high quality wire arc additive manufacturing

Cunningham, Chloe; Flynn, Joseph M.; Shokrani, Alborz; Dhokia, Vimal; Newman, Stephen T.

doi:10.1016/j.addma.2018.06.020

Cited by 352 publications

(227 citation statements)

References 118 publications

(153 reference statements)

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“…Alternatively, a plasma torch has been coupled with a six‐axis‐articulated robotic arm to produce stainless steel 3D structures. [ 142 ] Though the process was found to be less efficient in terms of material utilization, there was more flexibility in feeding powders instead of wire [ 143 ] and the surface morphology was more homogeneous than the well‐known cold metal transfer method. A thermal plasma has also been reported to simultaneously reduce GO flakes and weld the resulting graphene‐like phase sheets into 3D porous scaffolds possessing ultra‐low density, high‐yield strength, and stiffness for bone implant applications.…”

Section: Towards 3d‐printed Fabricationmentioning

confidence: 99%

Plasmas for additive manufacturing

Sui

Zorman

Sankaran

2020

Plasma Processes & Polymers

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Additive methods for manufacturing materials have recently emerged, particularly for the fabrication of three-dimensional architectures. Because of their long history in thin-film etching and deposition, plasmas offer unique advantages for many of the materials and surface processes associated with additive manufacturing. Here, we review recent efforts that have been primarily focused on the direct writing of patterned structures and the post-treatment of printed materials. Different configurations, materials, and applications are presented. Current challenges and a future outlook are also provided. 3D printing, additive manufacturing, microdischarges, nanotechnology, roll-to-roll

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Section: Towards 3d‐printed Fabricationmentioning

confidence: 99%

Plasmas for additive manufacturing

Sui

Zorman

Sankaran

2020

Plasma Processes & Polymers

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“…Consequently, WAAM has found applications in the aerospace and other industrial sectors [1,2]. In addition, WAAM is reported to deliver fully dense (>99.99%) Ti-6Al-4V components with virtually no defects [3].…”

Section: Introductionmentioning

confidence: 99%

Criticality of porosity defects on the fatigue performance of wire + arc additive manufactured titanium alloy

Biswal

Zhang

Syed

et al. 2019

International Journal of Fatigue

145

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This study was aimed at investigating the effect of internal porosity on the fatigue strength of wire + arc additive manufactured titanium alloy (WAAM Ti-6Al-4V). Unlike similar titanium alloys built by the powder bed fusion processes, WAAM Ti-6Al-4V seldom contains gas pores. However, feedstock may get contaminated that may cause pores of considerable size in the built materials. Two types of specimens were tested: (1) control group without porosity referred to as reference specimens; (2) designed porosity group using contaminated wires to build the specimen gauge section, referred to as porosity specimens. Test results have shown that static strength of the two groups was comparable, but the elongation in porosity group was reduced by 60% and its fatigue strength was 33% lower than the control group. The stress intensity factor range of the crack initiating pore calculated by Murakami's approach has provided good correlation with the fatigue life. The kink point on the data fitting curve corresponds well with the threshold value of the stress intensity factor range found in the literature. For predicting the fatigue limit, a modified Kitagawa-Takahashi diagram was proposed consisting of three regions depending on porosity size. Critical pore diameter was found to be about 100 micrometres.

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“…Wire + arc additive manufacturing (WAAM) uses arc power heat sources to deposit metal wire for the production of medium-complexity near-net-shape freeform components for large-scale structural applications. Typical materials for WAAM are structural metals, such as titanium, aluminum, steel or Inconel Ò (Ref 1,2). Using the WAMM process, a large additive subtractive integrated modular machine (LASIMM) is currently being developed in the European project LASIMM (Ref 3).…”

Section: Introductionmentioning

confidence: 99%

Numerical Investigation of the Effect of Rolling on the Localized Stress and Strain Induction for Wire + Arc Additive Manufactured Structures

Abbaszadeh

Hönnige

Martina

et al. 2019

J. of Materi Eng and Perform

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Cold rolling can be used in-process or post-process to improve microstructure, mechanical properties and residual stress in directed-energy-deposition techniques, such as the high deposition rate wire + arc additive manufacturing (WAAM) process. Finite element simulations of the rolling process are employed to investigate the effect of rolling parameters, in particular rolling load and roller profile radius on the residual stress field as well as plastic strain distribution for the profiled roller. The results show the response to rolling of commonly used structural metals in WAAM, i.e., AA2319, S335JR steel and Ti-6Al-4V, taking into account the presence of residual stresses. The rolling load leads to changes in the location and the maximum value of the compressive residual stresses, as well as the depth of the compressive residual stresses. However, the roller profile radius only changes the maximum value of these compressive residual stresses. Changing the rolling load influences the equivalent plastic strain close to the top surface of the wall as well as in deeper areas, whereas the influence of the roller profile radius is negligible. The plastic strain distribution is virtually unaffected by the initial residual stresses prior to rolling. Finally, design curves were generated from the simulations for different materials, suggesting ideal rolling load and roller profile combinations for microstructural improvement requiring certain plastic strains at a specific depth of the additive structure.

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Invited review article: Strategies and processes for high quality wire arc additive manufacturing

Cited by 352 publications

References 118 publications

Plasmas for additive manufacturing

Plasmas for additive manufacturing

Criticality of porosity defects on the fatigue performance of wire + arc additive manufactured titanium alloy

Numerical Investigation of the Effect of Rolling on the Localized Stress and Strain Induction for Wire + Arc Additive Manufactured Structures

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Invited review article: Strategies and processes for high quality wire arc additive manufacturing

Cited by 352 publications

References 118 publications

Plasmas for additive manufacturing

Plasmas for additive manufacturing

Criticality of porosity defects on the fatigue performance of wire + arc additive manufactured titanium alloy

Numerical Investigation of the Effect of Rolling on the Localized Stress and Strain Induction for Wire + Arc Additive Manufactured Structures

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Criticality of porosity defects on the fatigue performance of wire + arc additive manufactured titanium alloy