Abstract
The presented work deals with the development of a novel TIG hot-wire process for the additive manufacturing of metallic components, which, in contrast to previous arc processes, enables a significant increase in melting performance with simultaneously reduced heat input. This is achieved by means of an upstream resistance heating of the wire between two contact points within the hot wire feeding system. The torch, hot wire feeder and gas nozzle are designed in such a way that a constant bead geometry can be guaranteed regardless of the machining direction. On the one hand, this can improve the dimensional accuracy; on the other hand, an increase in productivity is achieved through a significant reduction of process times. Essential parts of the work include the simulation-supported development of the processing system, the design and implementation of an innovative process control system and the testing of the new technology.
Highlights
The increasing digitalization of industrial value chains requires the development of new, intelligent manufacturing technologies that are characterised by a high degree of automation but are capable of producing a wide range of complex component geometries in small quantities at low production costs
The majority of additive manufacturing technologies are based on the use of a wire or powdered filler material that is melted by laser, electron beam or arc processes [2,3,4], whereby the energy source is moved over the substrate by a robot or a CNC system according to the specified component geometry [5]
The melting rates of arc processes exceed those of beam-based processes by many times, so that a very high productivity can be achieved
Summary
The increasing digitalization of industrial value chains requires the development of new, intelligent manufacturing technologies that are characterised by a high degree of automation but are capable of producing a wide range of complex component geometries in small quantities at low production costs. GMAW welding processes with pulsed, spray or rotating arc have high melting rates [18], but the higher local heating of the components has a pronounced influence on the microstructure as well as the formation of residual stresses and distortion This often means that the mechanic and geometric requirements cannot be met [19]. An increase of the melt pool temperature can be achieved by plasma processes, which are characterised by a significantly more concentrated heat input [41, 42] Based on these findings, high-performance TIG hot wire processes have already been developed with the aim of increasing melting performance and welding speed.
Sign-in/Register to view highlights & summary Sign-in/Register to access full text options 
Free) 
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a call
