Model for the Prediction of Deformations in the Manufacture of Thin-Walled Parts by Wire Arc Additive Manufacturing Technology

Mikel Casuso,Aitzol Lamikiz,Trunal Bhujangrao,Teresa Artaza,Alfredo Suárez,Jaime Amondarain,Fernando Veiga,Eider Aldalur

doi:10.3390/met11050678

Abstract

Gas Metal Arc Welding (GMAW) is a manufacturing technology included within the different Wire Arc Additive Manufacturing alternatives. These technologies have been generating great attention among scientists in recent decades. Its main qualities that make it highly productive with a large use of material with relatively inexpensive machine solutions make it a very advantageous technology. This paper covers the application of this technology for the manufacture of thin-walled parts. A finite element model is presented for estimating the deformations in this type of parts. This paper presents a simulation model that predicts temperatures with less than 5% error and deformations of the final part that, although quantitatively has errors of 20%, qualitatively allows to know the deformation modes of the part. Knowing the part areas subject to greater deformation may allow the future adaptation of deposition strategies or redesigns for their adaptation. These models are very useful both at a scientific and industrial level since when we find ourselves with a technology oriented to Near Net Shape (NNS) manufacturing where deformations are critical for obtaining the final part in a quality regime.

Highlights

Additive Manufacturing (AM) is an emerging and promising field that is gaining increasing research attention and its applications in different industrial sectors are spreading day by day
Wire Arc Additive Manufacturing (WAAM) is a type of AM technique classified into Directed Energy Deposition (DED) technologies, where a metal wire acts as material feedstock and is melted by a heat source [1]
This ER70S-6 steel was provided in the form of commercial wire with a diameter of 1.2 mm, first 3 coils (Praxair, Danbury, CT, USA) and the last coil (Bohler, Düsseldorf, Germany), and 8 mm flat S235JR steel plates were used as a substrate

Summary

Introduction

Additive Manufacturing (AM) is an emerging and promising field that is gaining increasing research attention and its applications in different industrial sectors are spreading day by day. Wire Arc Additive Manufacturing (WAAM) is a type of AM technique classified into Directed Energy Deposition (DED) technologies, where a metal wire acts as material feedstock and is melted by a heat source [1]. It is inaccurate to see WAAM as opposed to traditional subtractive manufacturing technologies, but as complementary to them, since WAAM is still far from achieving final parts without dimensional inaccuracies and good surface quality. Because of this issue, subtractive manufacturing, like machining, is nowadays the usual finishing step for parts coming from WAAM.

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