Testing and initial verification of the world's first metal 3D printed bridge

Gardner, Leroy; Kyvelou, Pinelopi; Herbert, Gordon; Buchanan, Craig

doi:10.1016/j.jcsr.2020.106233

Cited by 151 publications

(101 citation statements)

References 16 publications

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“…The theoretical curves for the as-built 3.5 mm, as-built 8.0 mm and machined coupons are shown in Figures 14-16, respectively, alongside the average test results for Ex and ̅ xy (markers). The test results act as anchor points to the theoretical curves at θ =0° and θ = 90° since they feature directly in Equations ( 6)- (9).…”

Section: Variation Of Elastic Constants With Directionmentioning

confidence: 99%

Characterisation of the anisotropic response of wire and arc additively manufactured stainless steel

2021

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In contrast to conventional structural steel and stainless steel, wire and arc additively manufactured (WAAM) material can exhibit a strongly anisotropic response. To investigate the degree of anisotropy in WAAM sheet material, data obtained from tensile tests on machined and as‐built stainless steel coupons are utilised. The WAAM material was tested in three different loading directions relative to the deposition direction and the response was captured using digital image correlation; a summary of the key results is presented. In the elastic range, the observed mechanical response is characterised using an orthotropic plane stress material model, which requires the definition of two Young's moduli, the Poisson's ratio and the shear modulus. Good agreement between the test results and the theoretical predictions based on the orthotropic material model is demonstrated. In the inelastic range, to describe the anisotropic yielding of the material, the well‐known Hill's criterion utilising the 0.2% proof stresses is employed. Overall, the elastic and inelastic properties of the studied material are shown to vary significantly with the direction of loading.

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Section: Variation Of Elastic Constants With Directionmentioning

confidence: 99%

Characterisation of the anisotropic response of wire and arc additively manufactured stainless steel

2021

Self Cite

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“…In comparison to powder-bed fusion AM processes, the cost and manufacturing time of larger components built through WAAM is lower as the deposition rate is much higher, i.e., of the order 2-4 kg/h [6]. Recently, WAAM method has been successfully applied to manufacture various large-scale parts and structures i.e., marine propeller-bracket [7], stainless-steel diagrid column [8], landing gear rib [9] and a 12.5 m long metal footbridge [10]. Ding et al [4] confirmed that the limitations of the other AM processes are increasing the demand for the WAAM process.…”

Section: Introductionmentioning

confidence: 99%

A Study on Power-Controlled Wire-Arc Additive Manufacturing using a Data-driven Surrogate Model

Israr

Buhl

Bambach�

2021

Preprint

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Wire-Arc Additive Manufacturing (WAAM) provides an alternative for the production of various metal products needed in medium to large batch sizes due to its high deposition rates. However, the cyclic heat input in WAAM may cause local overheating. To avoid adverse effects on the performance of the part, interlayer dwelling and active cooling are used, but these measures increase the process time. Alternatively, the temperature during the WAAM process could be controlled by optimizing the welding power. The present work aims at introducing and implementing a novel temperature management approach by adjusting the weld-bead cross-section along with the welding power to reduce the heat accumulation in the WAAM process. The temperature evolution during welding of weld beads of different cross-sections is investigated and a database of the relation between optimal welding power for beads of various sizes and different pre-heating temperatures was established. The numerical results are validated experimentally with a block-shaped geometry. The results show that by the proposed method, the test shape made was welded with lower energy consumption and process time as compared to conventional constant-power WAAM. The proposed approach efficiently manages the thermal input and reduces the need for pausing the process. Hence, the defects related to heat accumulation might be reduced, and the process efficiency increased.

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“…In comparison to powder-bed fusion AM processes, the cost and manufacturing time of larger components built through WAAM is lower as the deposition rate is much higher, i.e., of the order 2-4 kg/h [6]. Recently, WAAM method has been successfully applied to manufacture various largescale parts and structures, i.e., marine propeller-bracket [7], stainless-steel diagrid column [8], landing gear rib [9], and a 12.5 m long metal footbridge [10]. Ding et al [4] confirmed that the limitations of the other AM processes are increasing the demand for the WAAM process.…”

Section: Introductionmentioning

confidence: 99%

A study on power-controlled wire-arc additive manufacturing using a data-driven surrogate model

Israr

Buhl

Bambach

2021

Int J Adv Manuf Technol

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Wire-arc additive manufacturing (WAAM) provides an alternative for the production of various metal products needed in medium to large batch sizes due to its high deposition rates. However, the cyclic heat input in WAAM may cause local overheating. To avoid adverse effects on the performance of the part, interlayer dwelling and active cooling are used, but these measures increase the process time. Alternatively, the temperature during the WAAM process could be controlled by optimizing the welding power. The present work aims at introducing and implementing a novel temperature management approach by adjusting the weld-bead cross-section along with the welding power to reduce the heat accumulation in the WAAM process. The temperature evolution during welding of weld beads of different cross-sections is investigated and a database of the relation between optimal welding power for beads of various sizes and different pre-heating temperatures was established. The numerical results are validated experimentally with a block-shaped geometry. The results show that by the proposed method, the test shape made was welded with lower energy consumption and process time as compared to conventional constant-power WAAM. The proposed approach efficiently manages the thermal input and reduces the need for pausing the process. Hence, the defects related to heat accumulation might be reduced, and the process efficiency increased.

show abstract

Testing and initial verification of the world's first metal 3D printed bridge

Cited by 151 publications

References 16 publications

Characterisation of the anisotropic response of wire and arc additively manufactured stainless steel

Characterisation of the anisotropic response of wire and arc additively manufactured stainless steel

A Study on Power-Controlled Wire-Arc Additive Manufacturing using a Data-driven Surrogate Model

A study on power-controlled wire-arc additive manufacturing using a data-driven surrogate model

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