Welding Process for the Additive Manufacturing of Cantilevered Components with the WAAM

Feucht, Thilo; Lange, Jörg; Waldschmitt, Benedikt; Schudlich, Anna‐Katharina; Klein, Marcus; Oechsner, Matthias

doi:10.1007/978-981-15-2957-3_5

Cited by 28 publications

(19 citation statements)

References 10 publications

Supporting

Mentioning

Contrasting

Unclassified

Order By: Relevance

“…Thereby, wire arc additive manufacturing (WAAM) of steel parts is mainly addressed. Recent investigations on low-alloyed steel [13][14][15][16] or high-alloyed steel [17,18] demonstrate the potential for these sectors.…”

Section: Introduction and State Of The Artmentioning

confidence: 99%

Reduction of Energy Input in Wire Arc Additive Manufacturing (WAAM) with Gas Metal Arc Welding (GMAW)

et al. 2020

View full text Add to dashboard Cite

Wire arc additive manufacturing (WAAM) by gas metal arc welding (GMAW) is a suitable option for the production of large volume metal parts. The main challenge is the high and periodic heat input of the arc on the generated layers, which directly affects geometrical features of the layers such as height and width as well as metallurgical properties such as grain size, solidification or material hardness. Therefore, processing with reduced energy input is necessary. This can be implemented with short arc welding regimes and respectively energy reduced welding processes. A highly efficient strategy for further energy reduction is the adjustment of contact tube to work piece distance (CTWD) during the welding process. Based on the current controlled GMAW process an increase of CTWD leads to a reduction of the welding current due to increased resistivity in the extended electrode and constant voltage of the power source. This study shows the results of systematically adjusted CTWD during WAAM of low-alloyed steel. Thereby, an energy reduction of up to 40% could be implemented leading to an adaptation of geometrical and microstructural features of additively manufactured work pieces.

show abstract

Section: Introduction and State Of The Artmentioning

confidence: 99%

Reduction of Energy Input in Wire Arc Additive Manufacturing (WAAM) with Gas Metal Arc Welding (GMAW)

et al. 2020

View full text Add to dashboard Cite

show abstract

“…Step" process developed by Fronius is used at the TU Darmstadt. In this process, the wire is mechanically retracted after the drop separation, allowing for the drop to have a defined shape and time to cool down [16][17][18][19][20].…”

Section: As Experimental Setup the "Cmt Cyclementioning

confidence: 99%

3D‐Printing with steel of a bolted connection

Erven¹,

Lange²,

Feucht³

2021

ce papers

View full text Add to dashboard Cite

Additive Manufacturing seems promising for the steel construction industry, especially for small components with complex shapes. With Wire‐and‐Arc‐Additive‐Manufacturing (WAAM) a process was found which is fast and cheap compared to other Additive Manufacturing processes for metals. Furthermore, arc‐welding is well known in steel construction industry. Bolted head plates are a common connection. Although they are relatively easy to produce, they are uneconomical in load transfer due to straining of the plates which are subject to bending. This type of connection is predestined for Additive Manufacturing. Rethinking the structure by taking into account the potentials of Additive Manufacturing brings a clear advantage compared to the conventional production. Thus, with a material saving of 60 % the same load capacity of the original flat head plate can be achieved. The paper shows how the new production process WAAM can significantly change the shape of structures on the example of a bolted head plate. Therefore, all steps from the original design to the manufactured structure are demonstrated, including the structure finding by using topology optimization, the manufacturing with different parameters and a first testing of the manufactured structures.

show abstract

“…A determined ratio of CMT cycles and pause time allows the drop to harden sufficiently so that its geometry is no longer significantly influenced by the following drop. The process and input parameters used are listed in Feucht et al (2020a). The process parameters can be edited via a Fronius CMT Advanced 4000 R power source in the "CMT Cycle Step" characteristic.…”

Section: Process Parametersmentioning

confidence: 99%

Additive manufacturing by means of parametric robot programming

et al. 2020

View full text Add to dashboard Cite

3D printing or additive manufacturing (AM) is now becoming a common technology in industry. The research activities in this area are constantly increasing, because with the high level of automation and the possibility to produce individual and complex structures, the advantages of additive manufacturing are promising. Most materials used in the construction industry can be used for additive manufacturing, for example steel and concrete. The print head (for example, a welding torch in the AM of steel) is mainly led by industrial robots, whose movements must be transferred from the 3D geometry files to be manufactured. In contrast to all-in-one systems, where hardware, software and printed material are coordinated, most robot-based AM systems are made of components from different manufacturers and branches. The objects to be manufactured are complex and the manufacturing parameters, which significantly influence the geometry and quality of the manufactured part, are manifold. This makes the workflow from the 3D model to the finished object difficult, especially because it is almost impossible to predict the exact manufactured structure geometry or layer height (which would be indispensable for accurate slicing). During the manufacturing process, deviations between the target and actual geometry can occur. In this paper, parametric robot programming (PRP) is presented, which allows flexible motion programming, and a quick and easy reaction to deviations between target and actual geometry during the manufacturing process. Complex geometries are divided into iso-curves whose mathematical functions are determined by means of polynomial regression. The robot can calculate the coordinates to be approached from these functions itself. This allows a simple adjustment of the manufacturing coordinates during the process as soon as target-actual deviations occur. The workflow from the file to the manufactured object is explained. The principle of PRP is transferable and applicable to all robot manufacturers and all conceivable printing processes. In the following article, it will be presented using wire + arc additive manufacturing, in which welding robots or portals can be used to produce steel structures with high deposition rates. Furthermore, the project "AM Bridge 2019" is presented, in which a steel bridge was manufactured in situ over a little creek and the presented PRP was applied.

show abstract

Welding Process for the Additive Manufacturing of Cantilevered Components with the WAAM

Cited by 28 publications

References 10 publications

Reduction of Energy Input in Wire Arc Additive Manufacturing (WAAM) with Gas Metal Arc Welding (GMAW)

Reduction of Energy Input in Wire Arc Additive Manufacturing (WAAM) with Gas Metal Arc Welding (GMAW)

3D‐Printing with steel of a bolted connection

Additive manufacturing by means of parametric robot programming

Contact Info

Product

Resources

About