Research challenges, quality control and monitoring strategy for Wire Arc Additive Manufacturing

Zahidin, Mohd Rozaimi; Yusof, Farazila; Abdul-Rashid, Salwa Hanim; Mansor, Safwan; Raja, Sufian; Jamaludin, Mohd Fadzil; Manurung, Yupiter Harangan Prasada; Adenan, Mohd Shahriman; Hussein, Nur Izan Syahriah

doi:10.1016/j.jmrt.2023.03.200

Cited by 33 publications

(6 citation statements)

References 104 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Thirdly, the integration of multi-systems including AM, IPD and online monitoring also could not be realized without the assistance of robotic automation. In addition, on the level of quality control [4,244], the development and application of process monitoring is also necessary. Initially, the utilization of charge coupled device cameras or infrared cameras in the process of AM as an in-situ detection and the adjustment of corresponding input parameters according to the detection feedback has become an important guarantee of forming quality.…”

Section: Equipment Developmentsmentioning

confidence: 99%

Performance-control-orientated hybrid metal additive manufacturing technologies: state of the art, challenges, and future trends

Lv,

Liang,

et al. 2024

Int. J. Extrem. Manuf.

View full text Add to dashboard Cite

Metal additive manufacturing (AM) technologies have made significant progress in the basic theoretical field since their invention in the 1970s. However, performance instability during continuous processing, such as thermal history, residual stress accumulation, and columnar grain epitaxial growth, consistently hinders their broad application in standardized industrial production. To overcome these challenges, performance-control-oriented hybrid AM (HAM) technologies have been introduced. These technologies, by leveraging external auxiliary processes, aim to regulate microstructural evolution and mechanical properties during metal AM. In this context, HAM technologies for molten pool regulation and solidified material deformation are identified as energy field-assisted AM (EFed AM, e.g., ultrasonic, electromagnetic, heat, etc.) technologies and interlayer plastic deformation-assisted AM (IPDed AM, e.g., laser shock peening, rolling, ultrasonic peening, friction stir process, etc.) technologies, respectively. A detailed and systematic review of performance-control-oriented HAM technologies is then provided. This review covers the influence of external energy fields on the melting, flow, and solidification behavior of materials, and the regulatory effects of interlayer plastic deformation on grain refinement, nucleation, and recrystallization. Furthermore, the role of performance-control-oriented HAM technologies in managing residual stress conversion, metallurgical defect closure, mechanical property improvement, and anisotropy regulation is thoroughly reviewed and discussed. The review concludes with an analysis of future development trends in EFed AM and IPDed AM technologies.

show abstract

Section: Equipment Developmentsmentioning

confidence: 99%

Performance-control-orientated hybrid metal additive manufacturing technologies: state of the art, challenges, and future trends

Lv,

Liang,

et al. 2024

Int. J. Extrem. Manuf.

View full text Add to dashboard Cite

show abstract

“…Likewise, accurate knowledge of RS is important to enhance product quality and ensure WAAM components meet their performance. By reducing the risk of defects, failures, rework, and/or remanufacture, it can lower production costs and minimize material waste [37,39,40].…”

Section: Overview Of Waam Of Process and Productsmentioning

confidence: 99%

Review of Measuring Methods of Residual Stress in Wire Arc Additive Manufacturing Products

Gurmesa,

Lemu,

Adugna

et al. 2024

Preprint

View full text Add to dashboard Cite

This literature review provides an in-depth exploration of the research conducted on the investigation and measurement of residual stress (RS) in Wire Arc Additive Manufacturing (WAAM) products, particularly focusing on how process parameters influence the phenomenon. RS plays a crucial role in determining the mechanical behavior and structural integrity of WAAM components. This review article gives an understanding of the relationship between process parameters and RS to optimize the WAAM processes and ensure the durability of the final products. It also summarizes key findings, measurement techniques, challenges, and future directions in this evolving field. The review also analyzes a measurement of RS in the products of WAAM as a function of process parameters depending on examining various research studies, techniques, and methodologies employed in their studies. Experimental measuring techniques and numerical analysis of RS to determine the impacts of RS in mechanical response in products of WAAM were discussed. By offering a comprehensive overview of current research trends and insights, this review serves as a valuable resource to guide future investigations, fostering the advancement of WAAM as a robust and efficient manufacturing technology.

show abstract

“…Although it is not financially feasible to replace the entire structure, there are some alternatives, like cutting the deposited region, putting fresh additive layers at the corroded surface, and sealing small gaps [13]. The use of AM systems, which create 3D structures layer-by-layer deposition, has grown in popularity since they need less time to produce, waste less material and environmental-friendly process [14][15][16][17]. This approach saves about half of manufacturing costs in contrast to the traditional techniques [18].…”

Section: Introductionmentioning

confidence: 99%

Metallurgical and mechanical properties of marine grade AA5356 using wire arc additive manufacturing

Jeyakumar,

Jayakumar

2024

Mater. Res. Express

View full text Add to dashboard Cite

In the current work, a Gas metal arc welding (GMAW)-based Wire Arc Additive Manufacturing (WAAM) procedure was used to build a wall construction of measuring Aluminium alloy (AA) AA5356 on an AA5083 base plate. The microstructure and mechanical properties of AA5356 were examined at two places along the wall structure’s horizontal deposition direction and in two deposition orientations (horizontal and vertical). Optical microscopy, SEM, EDAX, and fractographical examinations were used to analyse the microstructure. Tensile and microhardness tests were performed at two wall locations to evaluate mechanical parameters. A microstructure analysis reveals a mixture of columnar grain structure and coarser intermetallics in the remelting zone, with finer granular structure in the central region. The horizontal direction of AA5356 deposition exhibited a highest elongation and tensile strength of 4.4% and 249 MPa than the vertical direction. For the horizontal and vertical orientations, the average microhardness values were determined to be 80 HV and 72 HV, respectively. Fracture analysis of the tensile samples showed that the deposited metal had a ductile mode of failure with a predominance of dimples with tearing shape. This study provides valuable insights into constructing wall structures and analyzing their mechanical properties.

show abstract

Research challenges, quality control and monitoring strategy for Wire Arc Additive Manufacturing

Cited by 33 publications

References 104 publications

Performance-control-orientated hybrid metal additive manufacturing technologies: state of the art, challenges, and future trends

Performance-control-orientated hybrid metal additive manufacturing technologies: state of the art, challenges, and future trends

Review of Measuring Methods of Residual Stress in Wire Arc Additive Manufacturing Products

Metallurgical and mechanical properties of marine grade AA5356 using wire arc additive manufacturing

Contact Info

Product

Resources

About