This document provides an overview of Wire Arc Additive Manufacturing (WAAM). It describes WAAM as an additive manufacturing technique that uses an electric arc as an energy source and welding wire as a feedstock. WAAM allows for high deposition rates compared to powder-based methods. The document reviews academic studies on WAAM of aluminum components and modular path planning. It also discusses applications of WAAM in aerospace and comparisons between WAAM and powder laser melting methods.
Wire arc additive manufacturing (WAAM) is a crucial technique in the fabrication of 3D metallic structures. It is increasingly being used worldwide to reduce cost and time. Generally, AM technology is used to overcome the limitations of traditional subtractive manufacturing (SM) for fabricating large-scale components with lower buy-to-fly ratios. It became interesting for scientists and manufacturers due to its ability to produce fully dense metal parts and large near-net-shape products. WAAM is mostly used in modern industries, like aerospace industry. There are three heat sources commonly used in WAAM: metal inert gas welding (MIG), tungsten inert gas welding (TIG), and plasma arc welding (PAW). MIG is easier and more convenient than TIG and PAW because it uses a continuous wire spool with the welding torch. Unlike MIG, tungsten inert gas welding (TIG) and plasma arc welding (PAW) need an external wire feed machine to supply the additive materials. WAAM is gaining popularity in the fabrication of 3D metal components, but the process is hard to control due to its inherent residual stress and distortion, which are generated by the high thermal input from its heat sources. Distortion and residual stress are always a challenge for WAAM because they can affect the component’s geometric accuracy and drastically degrade the mechanical properties of the components.
Electron Beam Welding is a fusion welding process in which a beam of high-velocity electrons is applied to the material to be joined. The work-piece melt as the kinetic energy of the electrons is transformed into heat upon impact. The EBW process is well-positioned to provide industries with highest quality welds and machine designs that have proven to be adaptable to specific welding tasks and production environments.
What is laser beam hardening (LBH)? Advantages, Disadvantages
Applications, What is laser peening? Difference between laser beam hardening (LBH) and electron beam hardening (EBH)
Wire arc additive manufacturing (WAAM) is a crucial technique in the fabrication of 3D metallic structures. It is increasingly being used worldwide to reduce cost and time. Generally, AM technology is used to overcome the limitations of traditional subtractive manufacturing (SM) for fabricating large-scale components with lower buy-to-fly ratios. It became interesting for scientists and manufacturers due to its ability to produce fully dense metal parts and large near-net-shape products. WAAM is mostly used in modern industries, like aerospace industry. There are three heat sources commonly used in WAAM: metal inert gas welding (MIG), tungsten inert gas welding (TIG), and plasma arc welding (PAW). MIG is easier and more convenient than TIG and PAW because it uses a continuous wire spool with the welding torch. Unlike MIG, tungsten inert gas welding (TIG) and plasma arc welding (PAW) need an external wire feed machine to supply the additive materials. WAAM is gaining popularity in the fabrication of 3D metal components, but the process is hard to control due to its inherent residual stress and distortion, which are generated by the high thermal input from its heat sources. Distortion and residual stress are always a challenge for WAAM because they can affect the component’s geometric accuracy and drastically degrade the mechanical properties of the components.
Electron Beam Welding is a fusion welding process in which a beam of high-velocity electrons is applied to the material to be joined. The work-piece melt as the kinetic energy of the electrons is transformed into heat upon impact. The EBW process is well-positioned to provide industries with highest quality welds and machine designs that have proven to be adaptable to specific welding tasks and production environments.
What is laser beam hardening (LBH)? Advantages, Disadvantages
Applications, What is laser peening? Difference between laser beam hardening (LBH) and electron beam hardening (EBH)
Additive Manufacturing (2.008x Lecture Slides)A. John Hart
Slides accompanying 2.008x* video module on Additive Manufacturing, Prof. John Hart, MIT, 2016.
*Fundamentals of Manufacturing Processes on edX: https://www.edx.org/course/fundamentals-manufacturing-processes-mitx-2-008x
Explosive Forming is a manufacturing technique that uses explosions to force metal into dies and molds.
The explosives are typically either detonated underwater or in direct contact with the materials.
The technique is useful for short production runs of conventionally difficult-to-manufacture parts.
In Explosive Forming a punch or diaphragm in conventional forming is replaced by an explosive charge.
Chemical energy from the explosives is used to generate shockwaves through a medium (mostly water), which are directed to deform the workpiece at very high velocities.
One of the welding processes that used in Engineering field is the plasma arc welding. There are several types of welding processes similar to this, but plasma arc welding has its unique features.
Thanks for the colleagues who give this slides to publish.
This Presentation covers the basic concepts of Hot cracks and cold cracks in welding. For more information, please refer the books mentioned in the references slide.... Thank you
Additive Manufacturing (2.008x Lecture Slides)A. John Hart
Slides accompanying 2.008x* video module on Additive Manufacturing, Prof. John Hart, MIT, 2016.
*Fundamentals of Manufacturing Processes on edX: https://www.edx.org/course/fundamentals-manufacturing-processes-mitx-2-008x
Explosive Forming is a manufacturing technique that uses explosions to force metal into dies and molds.
The explosives are typically either detonated underwater or in direct contact with the materials.
The technique is useful for short production runs of conventionally difficult-to-manufacture parts.
In Explosive Forming a punch or diaphragm in conventional forming is replaced by an explosive charge.
Chemical energy from the explosives is used to generate shockwaves through a medium (mostly water), which are directed to deform the workpiece at very high velocities.
One of the welding processes that used in Engineering field is the plasma arc welding. There are several types of welding processes similar to this, but plasma arc welding has its unique features.
Thanks for the colleagues who give this slides to publish.
This Presentation covers the basic concepts of Hot cracks and cold cracks in welding. For more information, please refer the books mentioned in the references slide.... Thank you
MSEC2014-4063 THERMOMECHANICAL INVESTIGATION OF OVERHANG FABRICATIONS IN ELEC...The University of Alabama
Electron beam additive manufacturing (EBAM) is one of
powder-bed-fusion additive manufacturing processes that are capable of making full density metallic components. EBAM has a great potential in various high-value, small-batch productions in biomedical and aerospace industries. In EBAM, because a build part is immersed in the powder bed, ideally the process would not require support structures for overhang geometry. However, in practice, support structures are indeed needed for an overhang; without it, the overhang area will have defects such as warping, which is due to the complex thermomechanical process in EBAM. In this study, a thermomechanical finite element model has been developed to simulate temperature and stress fields when building a simple overhang in order to examine the root cause of overhang warping. It is found that the poor thermal conductivity of Ti- 6Al-4V powder results in higher temperatures, also slower heat dissipation, in an overhang area, in EBAM builds. The retained higher temperatures in the area above the powder substrate result in higher residual stresses in an overhang area, and lower powder porosity may reduce the residual stresses associated with building an overhang.
CONTINUOUS CASTING OF COPPER MAGNESIUM CONDUCTOR ALLOYSRautomead Limited
CONTINUOUS CASTING OF COPPER MAGNESIUM CONDUCTOR ALLOYS
Paper by Sir Michael Nairn, Chairman of Rautomead Limited, Dundee, Scotland, U.K.
The paper was presented at the WAI Technical Conference at Interwire, at the Georgia World Congress Center, Atlanta, Georgia, U.S.A., April 25, 2013.
Rautomead Limited are UK-based specialists in continuous casting of non-ferrous metals and construction of continuous casting equipment for copper, copper alloys, gold and silver, dental alloys and feed rod for Conform machines.
For a period of over 30 years Rautomead Limited has specialised in the design, manufacture and sale of continuous casting equipment for non-ferrous metals and alloys.
There are now more than 300 Rautomead machines in operation in over 45 different countries around the world.
Erosion and Cavitation Tests Applied to Coating Welded with Blends of Stainle...CSCJournals
The process GMAW with its your applications using two wires pointing in the market as an alternative to coating when high productivity is desired. Potential variants emerge from this process as GMAW cold wire and GMAW double wire. One of the biggest difficulty is the setting of its parameters, which in addition to duplicate compared to conventional GMAW, act in a dependent manner. A greater understanding of this technology applied to coatings on turbines in various positions is critical so that you can master the process and its variables, aiming to enhance the application in industry. It was proposed in this study an experimental evaluation to verify the influence of some variables on the profile of cord and wear resistance. For this it is proposed in this paper to make deposits with weld metal AWS 308LSi stainless steel and alloys of cobalt (Stellites 6 and 21) plates in carbon steel SAE 1020 in flat positions. In the characterization of wear in the lining was used the determination of the hardness and surface topography. It is concluded that cobalt alloys have superior resistance to erosive damage with emphasis on the Stellite 21 alloy in erosion and cavitation in Stellite 6. In an intermediate position with respect to wear are mixtures of austenitic stainless steel and cobalt alloys. Therefore, it is essential to study welding processes with multiple wires as proposed in this paper aiming the best combination of alloys for resistance to cavitation-erosion phenomena.
Parametric Optimization on MIG Welded EN8 Material Joints by using Taguchi Me...ijsrd.com
Welding is a manufacturing process, which is carried out for joining of metals. By MIG Welding it is possible to weld in all positions. Optimization of the parameter will be carried out by Taguchi method. We will use EN-8 material which is more use in Automobile parts. EN8 plate with dimensions 250mm x 125mm x 6mm with V- Groove 650.Where the input parameters are welding current, Wire feed and gas flow rate and output parameters are tensile strength and Hardness.
Effects of welding current and arc voltage on fcaw weld bead geometryeSAT Journals
Abstract Flux cored arc welding(FCAW) process is characterized with its high deposition rate and productivity. Control of the operating parameters in FCAW is essential to obtain high production rates and good quality welds. Bead on plate welds were carried out on mild steel plates to study the influence of welding current and arc voltage on weld bead geometry parameters. The weld bead coss-sections were metallographically investigated. The effects of these welding parameters were evaluated by measuring penetration depth, reinforcement height, bead width, wetting angle, electrod deposit area and plate fusion area. The bead cross-section area and the weld shape factor were calculated from the measured results. The effects of welding parameters on weld bead geometry have been presented by histograms. Key Words: Flux cored arc welding, arc welding parameters, weld bead geometry, weld shape factor
Overview of the fundamental roles in Hydropower generation and the components involved in wider Electrical Engineering.
This paper presents the design and construction of hydroelectric dams from the hydrologist’s survey of the valley before construction, all aspects and involved disciplines, fluid dynamics, structural engineering, generation and mains frequency regulation to the very transmission of power through the network in the United Kingdom.
Author: Robbie Edward Sayers
Collaborators and co editors: Charlie Sims and Connor Healey.
(C) 2024 Robbie E. Sayers
Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
Student information management system project report ii.pdfKamal Acharya
Our project explains about the student management. This project mainly explains the various actions related to student details. This project shows some ease in adding, editing and deleting the student details. It also provides a less time consuming process for viewing, adding, editing and deleting the marks of the students.
Automobile Management System Project Report.pdfKamal Acharya
The proposed project is developed to manage the automobile in the automobile dealer company. The main module in this project is login, automobile management, customer management, sales, complaints and reports. The first module is the login. The automobile showroom owner should login to the project for usage. The username and password are verified and if it is correct, next form opens. If the username and password are not correct, it shows the error message.
When a customer search for a automobile, if the automobile is available, they will be taken to a page that shows the details of the automobile including automobile name, automobile ID, quantity, price etc. “Automobile Management System” is useful for maintaining automobiles, customers effectively and hence helps for establishing good relation between customer and automobile organization. It contains various customized modules for effectively maintaining automobiles and stock information accurately and safely.
When the automobile is sold to the customer, stock will be reduced automatically. When a new purchase is made, stock will be increased automatically. While selecting automobiles for sale, the proposed software will automatically check for total number of available stock of that particular item, if the total stock of that particular item is less than 5, software will notify the user to purchase the particular item.
Also when the user tries to sale items which are not in stock, the system will prompt the user that the stock is not enough. Customers of this system can search for a automobile; can purchase a automobile easily by selecting fast. On the other hand the stock of automobiles can be maintained perfectly by the automobile shop manager overcoming the drawbacks of existing system.
COLLEGE BUS MANAGEMENT SYSTEM PROJECT REPORT.pdfKamal Acharya
The College Bus Management system is completely developed by Visual Basic .NET Version. The application is connect with most secured database language MS SQL Server. The application is develop by using best combination of front-end and back-end languages. The application is totally design like flat user interface. This flat user interface is more attractive user interface in 2017. The application is gives more important to the system functionality. The application is to manage the student’s details, driver’s details, bus details, bus route details, bus fees details and more. The application has only one unit for admin. The admin can manage the entire application. The admin can login into the application by using username and password of the admin. The application is develop for big and small colleges. It is more user friendly for non-computer person. Even they can easily learn how to manage the application within hours. The application is more secure by the admin. The system will give an effective output for the VB.Net and SQL Server given as input to the system. The compiled java program given as input to the system, after scanning the program will generate different reports. The application generates the report for users. The admin can view and download the report of the data. The application deliver the excel format reports. Because, excel formatted reports is very easy to understand the income and expense of the college bus. This application is mainly develop for windows operating system users. In 2017, 73% of people enterprises are using windows operating system. So the application will easily install for all the windows operating system users. The application-developed size is very low. The application consumes very low space in disk. Therefore, the user can allocate very minimum local disk space for this application.
Vaccine management system project report documentation..pdfKamal Acharya
The Division of Vaccine and Immunization is facing increasing difficulty monitoring vaccines and other commodities distribution once they have been distributed from the national stores. With the introduction of new vaccines, more challenges have been anticipated with this additions posing serious threat to the already over strained vaccine supply chain system in Kenya.
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Forklift Classes Overview by Intella PartsIntella Parts
Discover the different forklift classes and their specific applications. Learn how to choose the right forklift for your needs to ensure safety, efficiency, and compliance in your operations.
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Welcome to WIPAC Monthly the magazine brought to you by the LinkedIn Group Water Industry Process Automation & Control.
In this month's edition, along with this month's industry news to celebrate the 13 years since the group was created we have articles including
A case study of the used of Advanced Process Control at the Wastewater Treatment works at Lleida in Spain
A look back on an article on smart wastewater networks in order to see how the industry has measured up in the interim around the adoption of Digital Transformation in the Water Industry.
Water Industry Process Automation and Control Monthly - May 2024.pdf
Wire Arc Additive Manufacturing
1. Özel Metal Malzemeler ve Yenilikçi Proses
Teknolojileri Birimi
WIRE ARC ADDITIVE MANUFACTURING(WAAM)
2. CONTENTS
ADDITIVE MANUFACTURING(AM)
WIRE ARC ADDITIVE MANUFACTURING(WAAM)
ACADEMIC STUDIES
APPLICATIONS OF WAAM
SOME RESEARCHS of CRANFIELD UNIVERSITY
WAAM vs POWDER LASER MELTING
3. Additive Manufacturing(AM)
Additive Manufacturing (AM) is a technique where structures are produced by
adding and depositing material in a layer upon layer manner. AM is the
suitable method for geometric and material complexity.
Figure1. Flow Chart of the Additive Manufacturing Process
4. Metallic Additive Manufacturing Systems
• Wire Feed Systems:
The feed stock is wire, and the energy source for these units can include
electron beam, laser beam, and plasma arc. In general, wire feed systems are well
suited for high deposition rate processing.
Figure2. Generic illustration of an AM wire feed system
5. Wire Arc Additive Manufacturing(WAAM)
WAAM is a technology which has been investigated in last 30 years.It became
interesting for scientists and manufacturers due to its ability to produce fully
dense and larger metal parts. It uses existing welding equipment, electric arc as
energy source and welding wire as feedstock.
Figure3. A simple Waam system
6. Wire Arc Additive Manufacturing(WAAM)
While the material deposition rate is 2-10 g/min in laser-based methods, it
reaches 50-90 g/min in the WAAM method.
Figure4. Landing gear component
9. Wire Arc Additive Manufacturing of Aluminum Components
Introduction/Materials and Methods
For deposition, a solid wire electrode with a diameter of 1.0 mm was used.
Metallographic samples were taken from the middle part of the samples for
macrostructure analysis. Tensile test was conducted at room temperature with a
test speed of 3.2 mm/min.
Table1. Nominal composition of welding wires
Table2. Welding parameters used for sample processing
10. Wire Arc Additive Manufacturing of Aluminum Components
Results and Discussion
As shown in the figure5 and 6, the results from visual examination Al-4047
showed a more uneven geometry whereas, Al-5356 showed a smooth and uniform
wall surface.
Figure5. Manufactured Al-4047 sample Figure6. Manufactured Al-5356 sample
As shown in the figure7, no significant change in hardness values can be
detected along the buildup of Al-5356 whereas, hardness values of Al-4047 showed
an inhomogeneous profile.
Figure7. Hardness distribution depending on buildup height
11. Wire Arc Additive Manufacturing of Aluminum Components
Conclusion
According to the analysis results;
• A wide solidification range is more suitable for uniform deposition.
• Increased arc length result in higher dynamic forces , thus affecting
deposition accuracy.
• The low energy input (current / voltage) does not alter the geometric
accuracy of the wall structure.
• Bead width decreases with travel speed. Melt through depth decreases
significantly with travel speed.
• Increasing travel speed or decreasing current causes a decrease in melt
through depth and an increase in roughness.
12. Modular path planning solution for Wire + Arc Additive
Manufacturing
Accurate path planning is as important as selecting the optimum process
parameters.
Figure8. Sharped turn(a) vs corner division (b).
Figure9. Path generetion through width varition.
As shown in figure8, sharp turns should be
avoided, and instead replaced by corner
intersections. Similarly, a sudden width
variation can create irregular paths results in
significant defects. (Fig. 9a,9b)
13. A modular path planning solution for Wire + Arc Additive
Manufacturing
As shown in Fig. 10a, a simple straight wall contains three zones to
accommodate the different thermal conditions in the stages of deposition start,
steady state, and end. This parameters change must be done whichever path is
used. Additionally, if a section contains a width requiring specific deposition
parameters, a zone can be defined to account for that change in width. (Fig.
10b).
Figure10. Zones definition.
14. APPLICATIONS
WAAM offers a alternative to traditional manufacturing industries such as
aerospace, marine, automotive and architecture.
Aerospace is one of the main industries that is currently unlocking the full
potential of WAAM. For example, STELIA Aerospace has recently
created aluminium fuselage panels with stiffeners manufactured directly on the
surface, using the WAAM technology.
Figure11. Wing part produced by waam
15. Cranfield University
What they’ve deposited so far;
Ti-6Al-4V Aluminium Refractories
– Grade 5 – 2024 –Tungsten
– Grade 23 – 2319 –Molybdenum
Steels Inconel Bronze Copper
– Stainless (17-4 PH, 316L) – 625
– 718
• The largest metal parts of WAAM;
16. WAAM vs Powder Laser Melting
The Waam method has the potential to produce large-scale metallic parts due
to its high deposition rate, low equipment investment and low operating costs.
Waam materials have better mechanical properties than powder bed systems
materials and do not exhibit porosity problems.
However, geometrical and surface accuracy are lower compared to powder-
based processes.
Figure12. Comparison of AM methods.
17. REFERENCES
An Introduction to Wire Arc Additive Manufacturing. (2018, June 14). Retrieved from
https://amfg.ai/2018/05/17/an-introduction-to-wire-arc-additive-manufacturing/
WAAM - Wire Arc Additive Manufacturing. (n.d.). Retrieved from https://www.aircraft-
philipp.com/en/acp-additive-manufacturing/waam-wire-arc-additive-manufacturing/
Williams, S. W., Martina, F., Addison, A. C., Ding, J., Pardal, G., & Colegrove, P. (2016). Wire Arc
Additive Manufacturing. Material Science and Technology, 32(7), 641-647.
WAAMMat. (n.d.). Retrieved from https://waammat.com/
Ayan, Y., & Kahraman, N. (2018). METAL EKLEMELİ İMALAT: TEL ARK YÖNTEMİ VE
UYGULAMALARI. INTERNATIONAL JOURNAL OF 3D PRINTING TECHNOLOGIES AND DIGITAL
INDUSTRY, 2(3), 78-84.
Guo, N. & Leu, M.C. Front. Mech. Eng. (2013) 8: 215. https://doi.org/10.1007/s11465-013-0248-8
Frazier, W.E. J. of Materi Eng and Perform (2014) 23: 1917. https://doi.org/10.1007/s11665-014-0958-z
Köhler, M., Fiebig, S., Hensel, J., & Dilger, K. (2019). Wire and Arc Additive Manufacturing of
Aluminum Components. Metals, 9(608). doi::10.3390/met9050608