Ultracold-Wire and arc additive manufacturing (UC-WAAM)

Rodrigues, Tiago A.; Duarte, Valdemar R.; Miranda, Rosa Maria Mendes; Santos, Telmo G.; Oliveira, J.P.

doi:10.1016/j.jmatprotec.2021.117196

Cited by 69 publications

(18 citation statements)

References 16 publications

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“…An alternative GTAW setup was developed by Rodrigues et al [87], termed ultracold WAAM (UC-WAAM). Unlike conventional deposition where the electric arc is established between the electrode and workpiece, UC-WAAM establishes an arc between the electrode and the feedstock wire.…”

Section: Hardwarementioning

confidence: 99%

Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing

et al. 2021

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Processing of aluminum alloys by wire arc additive manufacturing (WAAM) gained significant attention from industry and academia in the last decade. With the possibility to create large and relatively complex parts at low investment and operational expenses, WAAM is well-suited for implementation in a range of industries. The process nature involves fusion melting of a feedstock wire by an electric arc where metal droplets are strategically deposited in a layer-by-layer fashion to create the final shape. The inherent fusion and solidification characteristics in WAAM are governing several aspects of the final material, herein process-related defects such as porosity and cracking, microstructure, properties, and performance. Coupled to all mentioned aspects is the alloy composition, which at present is highly restricted for WAAM of aluminum but received considerable attention in later years. This review article describes common quality issues related to WAAM of aluminum, i.e., porosity, residual stresses, and cracking. Measures to combat these challenges are further outlined, with special attention to the alloy composition. The state-of-the-art of aluminum alloy selection and measures to further enhance the performance of aluminum WAAM materials are presented. Strategies for further development of new alloys are discussed, with attention on the importance of reducing crack susceptibility and grain refinement.

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Section: Hardwarementioning

confidence: 99%

Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing

et al. 2021

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“…The interlayer temperature (IT) is one of several variables in the wire arc additive manufacturing (WAAM) processes. There are other important variables, such as the deposition material [1], the wire feed speed, and the travel speed [2]. The importance of monitoring IT comes from the interest in ensuring the repeatability of deposition between layers.…”

Section: Introductionmentioning

confidence: 99%

Combined effect of the interlayer temperature with travel speed on features of thin wall WAAM under two cooling approaches

Teixeira

Scotti²,

Jorge³

et al. 2023

Int J Adv Manuf Technol

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This work presents the evaluation of the interlayer temperature (IT) with travel speed (TS) combined effect for a given wire feed speed (WFS) on operational, geometrical, and metallurgical features of thin walls with the same width deposited by wire arc additive manufacturing (WAAM) with a low alloy steel, using or not active cooling. A preliminary experimental design was carried out to define a range of IT that could prevent the molten pool from running down and, then, be used in the main experimental design. The main tests were planned and performed to find different IT and TS combinations for a given WFS capable of depositing walls with the same target effective wall width. After selecting the parameters, six walls were deposited, three under natural cooling (NC) and three under near immersion active cooling (NIAC). A more significant temperature variability along the layer length (ΔT/ΔLL) is observed in increasing IT-TS combination and under NIAC. Regardless of the cooling approach, a worse surface aspect was observed with lower IT and TS. However, NC or NIAC do not affect the wall width (effective or external) or the layer height. On the other hand, they are affected by the IT with TS combination. A shorter production time was obtained on the walls with NIAC and higher IT-TS. No marked microstructural differences were observed comparing the walls, regardless of the cooling approach. However, microstructure tempering (hardness reduction) was observed in the walls deposited with NC using higher IT levels.

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“…Thus, the parts require machining to meet geometry and surface finish requirements. The use of welding conditions that minimize the energy input through CMT welding systems [ 23 ] can decrease the appearance of residual stresses.…”

Section: Introductionmentioning

confidence: 99%

Experimental Study on the Manufacturing of Steel Inclined Walls by Directed Energy Deposition Based on Dimensional and 3D Surface Roughness Measurements

et al. 2022

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Robotic-directed energy deposition has attracted the attention of the research community and industry as a process capable of producing large metallic parts. The selection of the manufacturing conditions is a critical step in improving the process efficiency and quality of the produced parts. The present work aims at analyzing the geometry and surface topography of walls built using several conditions and inclination angles, without additional supports except for the substrate. The walls were made of AWS A5.18. ER70S-6 steel using the Wire Arc Additive Manufacturing process. The study used both dimensional and 3D topography measurements to analyze the results. As findings, the travel speed played an important role in the size of the cross-section due to the heat input to the welding zone. Heat accumulation was a critical factor in the size and accuracy of the beads. Moreover, intermediate cooling provided structures with more uniform dimensions, smaller width, and higher layer growth. The inclination of the pieces influenced the width and uniformity of the beads, generating minor imperfections on the downside of the pieces because of gravity.

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Ultracold-Wire and arc additive manufacturing (UC-WAAM)

Cited by 69 publications

References 16 publications

Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing

Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing

Combined effect of the interlayer temperature with travel speed on features of thin wall WAAM under two cooling approaches

Experimental Study on the Manufacturing of Steel Inclined Walls by Directed Energy Deposition Based on Dimensional and 3D Surface Roughness Measurements

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