WAAM process for metal block structure parts based on mixed heat input

Cui, Junyi; Yuan, Lei; Commins, Philip; He, Fengyang; Wang, Jun; Pan, Zengxi

doi:10.1007/s00170-021-06654-x

Cited by 20 publications

(5 citation statements)

References 62 publications

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“…For example, Xiong et al [17] reported that the parallel contour strategy could cause heat accumulation if the trajectory starts applying an outside-in direction. On the other hand, Cui et al [27] showed better-performed printing using outside-in, considering that the first external bead deposition serves as a limiting wall to guarantee dimensional accuracy. The spiral contour deposition strategy claims, to some extent, to balance the benefits and setbacks of the deposition direction.…”

Section: Resultsmentioning

confidence: 99%

Development and implementation of a software for wire arc additive manufacturing preprocessing planning: trajectory planning and machine code generation

2022

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To overcome a shortage of flexible and low-cost solutions for wire arc additive manufacturing (WAAM) preprocessing, this work’s objective was to develop and validate an in-house computational programme in an open-source environment for WAAM preprocessing planning. Algorithms for reading STL (stereolithography) files and implementing rotation, slicing, trajectory planning, and machine code generation were elaborated and implemented in the Scilab environment (free and open-source). A graphical interface was developed to facilitate user interaction, with 5 options for path planning. The functionality of each work step is detailed. For validation of the software, single and multiple-layer prints, with different geometrical complexity and printing challenges, were built in a CNC table geared by the generated machine code. The validation criteria were deposition imperfection, morphological, and dimensional tolerances. The outputs showed that the parts were successfully printed. Therefore, this work demonstrates that Scilab provides the necessary resources for companies and universities to implement and/or develop algorithms for planning and generating trajectories for WAAM. Moreover, emerging ideas can be reasonably easily implemented in such software, not always possible in commercial packages.

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Section: Resultsmentioning

confidence: 99%

Development and implementation of a software for wire arc additive manufacturing preprocessing planning: trajectory planning and machine code generation

2022

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“…Based on observations, the main factor contributing to the presence of the transition area is the response time of the process, which can be influenced by two factors: machine delay time, and process transition time [21]. The delay time of the wire feeder was measured, and various parameters (including WFS, current, voltage, and others) were recorded during the deposition process.…”

Section: Transition Area Studymentioning

confidence: 99%

Automated Interlayer Wall Height Compensation for Wire Based Directed Energy Deposition Additive Manufacturing

Qin,

Vives,

Raja

et al. 2023

Sensors

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Part quality monitoring and control in wire-based directed energy deposition additive manufacturing (w-DEDAM) processes has been garnering continuous interest from both the academic and industrial sectors. However, maintaining a consistent layer height and ensuring that the wall height aligns closely with the design, as depicted in computer-aided design (CAD) models, pose significant challenges. These challenges arise due to the uncertainties associated with the manufacturing process and the working environment, particularly with extended processing times. To achieve these goals in an industrial scenario, the deposition geometry must be measured with precision and efficiency throughout the part-building process. Moreover, it is essential to comprehend the changes in the interlayer deposition height based on various process parameters. This paper first examines the behaviour of interlayer deposition height when process parameters change within different wall regions, with a particular focus on the transition areas. In addition, this paper explores the potential of geometry monitoring information in implementing interlayer wall height compensation during w-DEDAM part-building. The in-process layer height was monitored using a coherent range-resolved interferometry (RRI) sensor, and the accuracy and efficiency of this measurement were carefully studied. Leveraging this information and understanding of deposition geometry, the control points of the process parameters were identified. Subsequently, appropriate and varied process parameters were applied to each wall region to gradually compensate for wall height. The wall height discrepancies were generally compensated for in two to three layers.

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“…In the case of WAAM, wide spaces between tracks are necessary due to the width of the beads and their spreading-out character obtained by different welding processes and techniques. For example, Cui et al (2021), depositing a nickel-aluminium-bronze alloy, found layers (with a single pass, or track, deposition per layer) with dimensions ranging from 3.2 to 9.0 mm in width and from 2.6 to 4.5 mm in height, using the gas metal arc welding-cold metal transfer (GMAW-CMT) and GMAW-pulsed processes, respectively. Using carbon steel, Teixeira et al (2022) elaborated a working envelope also with a single deposition pass per layer, covering layer dimensions ranging from 4.8 to 8.1 mm in width and 1.7 to 3.5 mm in height, using GMAW-CMT.…”

Section: Introductionmentioning

confidence: 99%

Enhanced-pixel strategy for wire arc additive manufacturing trajectory planning: operational efficiency and effectiveness analyses

Ferreira,

Vilarinho,

Scotti

2023

RPJ

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Purpose This study aims to propose and evaluate the progress in the basic-pixel (a strategy to generate continuous trajectories that fill out the entire surface) algorithm towards performance gain. The objective is also to investigate the operational efficiency and effectiveness of an enhanced version compared with conventional strategies. Design/methodology/approach For the first objective, the proposed methodology is to apply the improvements proposed in the basic-pixel strategy, test it on three demonstrative parts and statistically evaluate the performance using the distance trajectory criterion. For the second objective, the enhanced-pixel strategy is compared with conventional strategies in terms of trajectory distance, build time and the number of arcs starts and stops (operational efficiency) and targeting the nominal geometry of a part (operational effectiveness). Findings The results showed that the improvements proposed to the basic-pixel strategy could generate continuous trajectories with shorter distances and comparable building times (operational efficiency). Regarding operational effectiveness, the parts built by the enhanced-pixel strategy presented lower dimensional deviation than the other strategies studied. Therefore, the enhanced-pixel strategy appears to be a good candidate for building more complex printable parts and delivering operational efficiency and effectiveness. Originality/value This paper presents an evolution of the basic-pixel strategy (a space-filling strategy) with the introduction of new elements in the algorithm and proves the improvement of the strategy’s performance with this. An interesting comparison is also presented in terms of operational efficiency and effectiveness between the enhanced-pixel strategy and conventional strategies.

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WAAM process for metal block structure parts based on mixed heat input

Cited by 20 publications

References 62 publications

Development and implementation of a software for wire arc additive manufacturing preprocessing planning: trajectory planning and machine code generation

Development and implementation of a software for wire arc additive manufacturing preprocessing planning: trajectory planning and machine code generation

Automated Interlayer Wall Height Compensation for Wire Based Directed Energy Deposition Additive Manufacturing

Enhanced-pixel strategy for wire arc additive manufacturing trajectory planning: operational efficiency and effectiveness analyses

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