The state-of-the-art of wire arc directed energy deposition (WA-DED) as an additive manufacturing process for large metallic component manufacture

Costello, Sam C.A.; Cunningham, Chloe; Xu, Fujun; Shokrani, Alborz; Dhokia, Vimal; Newman, Stephen T.

doi:10.1080/0951192x.2022.2162597

Cited by 20 publications

(4 citation statements)

References 171 publications

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“…Partitioning is a key method utilized in LDM to mitigate residual stresses and minimize deformation Figure 1 shows a typical large structural component. With the development of additive manufacturing technology, metal additive manu facturing components entail challenges as large-scale, complex structures regarding con figuration topology, structure-function integration, and gradient composite [24]. Tradi tional partitioning methods face some challenges such as lengthy preparation times fo forming process documentation, limited portability across different components, and in adequate quality stability.…”

Section: Feature Partitioningmentioning

confidence: 99%

Research on the Deformation Prediction Method for the Laser Deposition Manufacturing of Metal Components Based on Feature Partitioning and the Inherent Strain Method

Li,

Gao,

Yin

et al. 2024

Mathematics

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Laser deposition manufacturing (LDM) has drawn unprecedented attention for its advantages in manufacturing large-scale and complex metal components. During the process of LDM, a large thermal gradient is generated due to thermal cycling and heat accumulation. As a result, large residual stress and deformation are formed in the LDM metal components. Then, the dimensional accuracy of the metal components becomes poor. To achieve deformation control and increase dimensional accuracy, the deformation prediction of metal components is very meaningful and directional. However, the traditional thermoelastic–plastic method can only achieve deformation prediction for small-scale LDM metal components. Because of the low computational efficiency, it is extremely difficult to meet deformation prediction demand for large-scale metal components. Based on feature partitioning and the inherent strain method, a rapid deformation prediction method is proposed for large-scale metal components in this manuscript. Firstly, to solve the problem of poor consistency of formation quality due to the randomness of the partition process, the partitioning process was established according to typical geometric features. Secondly, the inherent strain values for different partitions were obtained by considering the effects of the extraction method, mesh size, equivalent value layer, and partition size on the inherent strain values. Then, using the inherent strain method, the deformation of large-scale components was predicted rapidly. Comparing the simulation results with the experimental results, the following conclusions were obtained. The deformation predicted by the method proposed in this manuscript is consistent with the deformations predicted using the traditional thermoelastic–plastic method and the experimental method. Significantly, applying the method proposed in this manuscript to predict the deformation of LDM metal components, computational efficiency is improved by 27.25 times compared with results using the conventional thermoelastic–plastic method.

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Section: Feature Partitioningmentioning

confidence: 99%

Research on the Deformation Prediction Method for the Laser Deposition Manufacturing of Metal Components Based on Feature Partitioning and the Inherent Strain Method

Li,

Gao,

Yin

et al. 2024

Mathematics

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“…Different types of materials like plastics [55,56], concrete [57,58], composites [59,60], elastomers [61,62], polymers [63][64][65], metals and alloys [66][67][68][69][70][71][72], and non-metals [73,74] can be used for developing components. Commonly used 3D printing processes for stainless steel alloys, aluminum alloys, titanium alloys, and super alloys are laser powder bed fusion (LPBF) [75][76][77][78][79][80][81][82][83] wire arc direct energy deposition [84][85][86], laser metal deposition [87,88], and additive friction stir deposition [89][90][91] processes. The current research in additive manufacturing on aluminum alloys [92][93][94][95][96][97][98][99][100][10...…”

Section: Introductionmentioning

confidence: 99%

Recent Advancements in Material Waste Recycling: Conventional, Direct Conversion, and Additive Manufacturing Techniques

Golvaskar,

Ojo,

Kannan

2024

Recycling

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To improve the microstructure and mechanical properties of fundamental materials including aluminum, stainless steel, superalloys, and titanium alloys, traditional manufacturing techniques have for years been utilized in critical sectors including the aerospace and nuclear industries. However, additive manufacturing has become an efficient and effective means for fabricating these materials with superior mechanical attributes, making it easier to develop complex parts with relative ease compared to conventional processes. The waste generated in additive manufacturing processes are usually in the form of powders, while that of conventional processes come in the form of chips. The current study focuses on the features and uses of various typical recycling methods for traditional and additive manufacturing that are presently utilized to recycle material waste from both processes. Additionally, the main factors impacting the microstructural features and density of the chip-unified components are discussed. Moreover, it recommends a novel approach for recycling chips, while improving the process of development, bonding quality of the chips, microstructure, overall mechanical properties, and fostering sustainable and environmentally friendly engineering.

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“…Additionally, WAAM, which is a subset of AM, is getting significant interest from all researchers because of its various benefits, including its ability to achieve high metal deposition rates and produce near-net shapes, surpassing conventional manufacturing methods with its higher thermal residual stresses (RS) [3,[14][15][16]. It is an emerging metal additive manufacturing technique, that is gradually providing a competitive edge over traditional forging and casting methods [17]. Depending on the heat sources, the WAAM process is categorized into three; namely inert gas welding, metal arc welding, and plasma arc [18,19].…”

Section: Introductionmentioning

confidence: 99%

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

Gurmesa,

Lemu,

Adugna

et al. 2024

Preprint

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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.

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The state-of-the-art of wire arc directed energy deposition (WA-DED) as an additive manufacturing process for large metallic component manufacture

Cited by 20 publications

References 171 publications

Research on the Deformation Prediction Method for the Laser Deposition Manufacturing of Metal Components Based on Feature Partitioning and the Inherent Strain Method

Research on the Deformation Prediction Method for the Laser Deposition Manufacturing of Metal Components Based on Feature Partitioning and the Inherent Strain Method

Recent Advancements in Material Waste Recycling: Conventional, Direct Conversion, and Additive Manufacturing Techniques

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

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