The document discusses wire arc additive manufacturing (WAAM). WAAM uses an electric arc to melt and deposit wire material in layers to build 3D objects. It provides advantages over conventional manufacturing like reduced waste. The authors plan to retrofit a CNC mill with WAAM capabilities and conduct experiments on deposition parameters and properties of manufactured parts. Their objectives are to build a basic WAAM system using standard welding equipment, conduct process planning, deposition and post-processing experiments, and compare results to previous work.

1. Wire Arc Additive Manufacturing
-retrofitting on a CNC mill
Presented By: Hatim Godhrawala, Gaurav Dubey & Laxman Nagar
Guided By: Prof. Jignesh Patel
1. TENTATIVE PROJECT AREA
2. INTRODUCTION
3. LITERATURE REVIEW
4. SURVEY OR DATA COLLECTION
5. PROBLEMS STATEMENTS /
SUMMARY
6. TENTATIVE AIM /OBJECTIVES/
WORK PLAN

2. Introduction
WAAM is the most advanced technique used for additive manufacturing of metals. In this process, the wire as
feed material and arc as power source. The welding torch/power source, wire feeding mechanism and computer
control base, are the main components of the WAAM system. The computer control system is used to control the
wire feed and arc generation to facilitate controlled metal deposition to produce desired objects. In the WAAM
process, the desired part is fabricated through layer-by-layer deposition of material.
Comparing with the conventional additive manufacturing process, the mechanical and metallurgical properties of a
WAAM based products are much better and they are suited for aerospace engineering materials. Tungsten inert gas
welding (TIG), metal inert gas welding (MIG) and cold metal transfer (CMT) welding are the different welding
techniques using for deposition of metals.[2]

3. Basic Diagram Of WAAM Process

4. Principle of WAAM Process
Wire arc additive manufacturing (WAAM) is a fusion manufacturing process in which the heat energy of an
electric arc is employed for melting the electrodes and depositing material layers for wall formation or for
simultaneously cladding two materials in order to form a composite structure. This directed energy deposition‐arc
(DED‐arc) method is advantageous and efficient as it produces large parts with structural integrity due to the high
deposition rates, reduced wastage of raw material, and low consumption of energy in comparison with the
conventional joining processes and other additive manufacturing technologies.[10]

5. One example of the successful application of WAAM are the fan
impellers used in the electronics industry, which are made from high-
quality materials. Milling the workpiece is very expensive due to the
high rate of material consumption. Casting is also not always able to
meet the critical metallurgical properties required for walls just 1.5 mm
thick. WAAM can be used to additively manufacture and repair this
type of fan impeller blade using nickel-based alloys.
WAAM is also used to manufacture titanium components in the
aviation industry. These components would otherwise usually be
milled, causing up to 90 percent of the material to be lost and resulting
in high costs, long machining times, and costly tool wear. With
WAAM, however, the only additional work that is required is to smooth
component surfaces. Components produced do not exhibit any problems
with lack of fusion and have impressive metallurgical properties. This
also leads to reduced processing times, wear, and manufacturing Costs.

6. Some examples of WAAM Used in Current Scenerios
WAAM used for making Rockets: by Relativity Space
The British Aircraft Research Association Limited reduced material usage by 73%, cut
production time, and overall cost by using WAAM technology through WAAM3D to print this
aluminium nose cone (Source: Aircraft Research Association Limited)

7. Problem Statement
In comparison to traditional subtractive fabrication technologies, additive manufacturing (AM) is an
additional technique for fabricating complex metal components in a layer-by-layer manner. AM can
potentially reduce energy consumption and materials waste and numerous processes have been successfully
established for conventional metals
An advantage is that WAAM only requires a suitable welding system: expensive, specialist equipment is
simply not needed.
There are also a number of certified wires already available for the arc process. There are relatively few
materials available for powder-based processes, as it can take years to acquire the necessary certification and
to produce data sheets, since the use of metal powder is a relatively new Technology.

8. Literature Survey and Data Collection
No. TITLE AUTHOR YEAR CONCLUSION
1. DESIGN AND DEVELOPMENT OF A LOW-
COST 3D METAL PRINTER
N. A. Rosli1, M. R. Alkahari, F. R.
Ramli, S. Maidin, M. N. Sudin, S.
Subramoniam, T. Furumoto
2018
2. “Wire arc additive manufacturing of aluminium
alloys - A review”
K.E.K. Vimal, M. Naveen
Srinivas, Sonu Rajak
2020
3. Wire Arc Additive Manufacturing (WAAM)
process of nickel based superalloys
V. Dhinakaran a,⇑, J. Ajith a, A.
Fathima Yasin Fahmidha a, T.
Jagadeesha b, T. Sathish c, B.
Stalin d
2019
4. Wire + Arc Additive Manufacturing S. W. Williams, F. Martina, A. C.
Addison, J. Ding, G. Pardal & P.
Colegrove
2016
5. Influence of pulsed arc on the metal droplet
deposited by projected transfer mode in wire-
arc additive manufacturing”
Luo Yi, Li Jinglong, Xu Jie, Zhu
Liang, Han Jingtao, Zhang
Chengyang
2018

9. Literature Survey and Data Collection
No. TITLE AUTHOR YEAR CONCLUSION
6. Comparative study of eutectic Al-Si alloys
manufactured by WAAM and casting.
Langelandsvik, G., Horgar, A., Furu,
T. et al.
2020
7. “Design and Testing of a WAAM Retrofit Kit
for Repairing Operations on a Milling Machine
Gianni Campatelli, Giuseppe
Venturini , Niccolò Grossi,
Francesco Baffa, Antonio Scippa
and Kazuo Yamazaki
2021
8. Applications of Open Source GMAW-Based
Metal 3-D Printing”
Yuenyong Nilsiam 1 ID , Paul G.
Sanders 2 and Joshua M. Pearce
2018
9. The Current State of Research of Wire Arc
Additive Manufacturing (WAAM):
Kai Treutler * and Volker Wesling 2021
10. Wire Arc Additive Manufacturing: Review on
Recent Findings and Challenges in Industrial
Applications and Materials Characterization
Mukti Chaturvedi 1, Elena
Scutelnicu 2,*, Carmen Catalina
Rusu 2, Luigi Renato Mistodie 2,
Danut Mihailescu 2 and Arungalai
Vendan Subbiah 1
2021

10. Objective
A basic WAAM system that consists of a combination of a motion system, welding equipment and feedstock.
Our objective is to make a basic WAAM system. WAAM hardware will currently use standard, off the shelf welding
equipment: welding power source, torches and wire feeding systems. Motion can be provided computer numerical
controlled gantries. The retrofitted machine features a bed, which is 1.5mx1.5m in size.
Complete WAAM process divided into three steps namely process planning, metal deposition, & post processing.
Process planning includes- 3D CAD model generation, set of 2D geometries can be obtained by slicing 3D CAD
model, generating tool path for each of these 2D geometries, setting deposition parameters for each layer, choosing
welding parameters like travel speed, feed rate, voltage, etc.
Metal Deposition: The product can be deposited by WAAM process with given input parameters and tool path.
Post Processing: With a set of methods we improve the metallurgical and mechanical properties

11. WorkPlan
July-Aug Sept-Oct Nov-Dec Jan-Feb March- April May-June
Literature
Review
Literature
Survey and
Experimental
Setup
Experimental
Setup and
Experimentation
Test,
Comparison
Experiments
Test,
Comparison
Experiments
Conclusion of
Experiments

12. Methodology
1. Literature Review: Researching and reviewing past research papers that are written around our
field of interest. Compiling this data to setup a reference database that can help in further research.
2. Experimental Setup: Building the WAAM machine. Testing and prototyping different parts to make
it work. Solving different problems that arises while building the machine.
3. Experimentation: Once machine starts working as expected, different experiments will be held to
analyse different variables and patterns.
4. Test and Comparison: Comparing our experiments with the past researchers data to get a
benchmark of our setup.
5. Conclusion: At the end of project, concluding our work with a proper application and finding the
future improvements.

13. References
1. “DESIGN AND DEVELOPMENT OF A LOW-COST 3D METAL PRINTER” N. A. Rosli, M. R. Alkahari, F. R. Ramli, S. Maidin, M. N.
Sudin, S. Subramoniam, T. Furumoto
2. “Wire arc additive manufacturing of aluminium alloys: A review” K.E.K. Vimal, M. Naveen Srinivas, Sonu Rajak
3. “Wire Arc Additive Manufacturing (WAAM) process of nickel based superalloys – A review” V. Dhinakaran, J. Ajith a, A. Fathima
Yasin Fahmidha, T. Jagadeesha b, T. Sathish, B. Stalin
4. “Wire + Arc Additive Manufacturing” S. W. Williams, F. Martina, A. C. Addison, J. Ding, G. Pardal & P. Colegrove
5. “Influence of pulsed arc on the metal droplet deposited by projected transfer mode in wire-arc additive manufacturing” Authors:
Luo Yi, Li Jinglong, Xu Jie, Zhu Liang, Han Jingtao, Zhang Chengyang
6. “Comparative study of eutectic Al-Si alloys manufactured by WAAM and casting.” Langelandsvik, G., Horgar, A., Furu, T. et al.
7. “Design and Testing of a WAAM Retrofit Kit for Repairing Operations on a Milling Machine” Gianni Campatelli, Giuseppe Venturini,
Niccolò Grossi, Francesco Baffa, Antonio Scippa and Kazuo Yamazaki
8. “Applications of Open Source GMAW-Based Metal 3-D Printing” Yuenyong Nilsiam ID , Paul G. Sanders and Joshua M. Pearce
9. “The Current State of Research of Wire Arc Additive Manufacturing (WAAM): A Review” Kai Treutler and Volker Wesling
10. “Wire Arc Additive Manufacturing: Review on Recent Findings and Challenges in Industrial Applications and Materials
Characterization” Mukti Chaturvedi, Elena Scutelnicu, Carmen Catalina Rusu, Luigi Renato Mistodie, Danut Mihailescu and Arungalai Vendan Subbiah