Abstract
Arc-welding based additive manufacturing is a cost-efficient, productive technology which has been shown to be capable of producing high-integrity components. It is suggested that in automotive engineering, this manufacturing process can be used to reinforce body components by generating stiffening elements. Benefits of this method could be more flexural rigidity with comparatively lower material volume. In the current study, wire arc additive manufacturing (WAAM) with an advanced short arc welding process with low heat input was chosen. The first objective of the work was to check possibility of generating a gusset plate on zinc-coated car body parts by additive manufacturing, for reinforcing of formed thin steel sheets. The second aim was to increase flexural rigidity of the sheets by depositing weld metal as a grid. Bending tests of the sheets indicated an increased flexural rigidity compared with the parent material. This production method and the results of this study are related to automotive engineering but could be employed for other applications. The aim is to demonstrate how these goals could be approached, what difficulties and limitations exist, and where further research work could be initiated.
Highlights
Wire arc additive manufacturing “Wire arc additive manufacturing (WAAM)” has been recognized as a relatively rapid, cost-effective alternative for generating metal components [1]
wire arc additive manufacturing (WAAM) could be used for creating local stiffening elements to reinforce critical body parts
On the one hand, targeted flat surfaces and complex dimensioned components could be locally stiffened by welding on one-layer welding, or, on the other hand, small, effective stiffening ribs can be welded into the body contour using local WAAM multilayer seams
Summary
Wire arc additive manufacturing “Wire arc additive manufacturing (WAAM)” has been recognized as a relatively rapid, cost-effective alternative for generating metal components [1]. High deposition rates and lower investment and operating costs compared with powder-based additive manufacturing processes are of particular interest for the production of largevolume components [2]. WAAM seems to be one of the most promising technologies for additive manufacturing It is known for high productivity, high energy efficiency, and low raw material cost [3]. Compared with other metal additive manufacturing processes with the wire and arc additive manufacturing. Further benefits are flexibility in shape and material of the component, material savings compared to forged parts, no necessary forming tools, short-term conversion to other shapes and materials is possible, high material quality due to the heat treatment coupled with the process in multilayer welding, in particular uniform and isotropic toughness as well as adding material to an already existing workpiece [1]
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