Evaluation of Single Wall Builds Using Wire Arc Additive Manufacturing

Abstract

Abstract Wire Arc Additive Manufacturing (Wire Arc AM) offers advantages in producing large-scale components at lower costs, making it a promising technology. It holds the promise of revolutionizing the manufacturing industry, offering a versatile approach for producing intricate and large-scale metal components. In this paper, we present initial findings from our ongoing research project that is centered on investigating the potential of using ER 120S-G steel as a printing material for part designs featuring diverse geometric features in order to assess the manufacturability of part designs using Wire Arc AM. The selection of ER 120S-G steel as the material for this study was deliberate. This steel, known for its weldability and high strength, was chosen because of its history of application in welding high-strength steel structures. This paper focuses on a multi-faceted approach involving the analysis of four distinct builds. There are many aspects that effect the overall quality of a part that is built using Wire Arc AM that include Process Parameters, Machine Setup, Process, Build Quality, and Process Capability. At first, we systematically evaluate the impact of machine parameters, gas compositions, wire feed speed, and trigger modes on single layer bead quality. We used the knowledge from the single layer bead study to print four single wall builds. Each build tested a different machine or process parameter, while also striving to mitigate quality defects. Build 3, aiming for a final height of 95mm, marked a substantial improvement in build quality, showcasing the smoothest walls and overall top-level smoothness. Although each build presented unique challenges, they collectively contributed to the ongoing refinement of the machine and process parameters needed to achieve the desired geometry. Finally, we present the results from the four builds highlighting the importance of precise machine setup and parameter selection. This research provides valuable insights to optimize Wire Arc AM parameters for good quality of geometric features and represents a significant step forward in our understanding of Wire Arc AM with ER 120S-G steel. The insights gained from the systematic evaluation of the four single wall builds, machine setup, material selection, parameter optimization, and analysis of builds will serve as a valuable foundation for future research in the field. This project sets the stage for the development of design rules and best practices tailored for Wire Arc AM, with the future work focused on establishing manufacturability design rules, creating a formalized assessment for future designs to determine overall manufacturability risks for using Wire Arc AM, and enhancing Wire Arc AM capabilities.