Browsing by Author "Aldalur, Eider"
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Item Analysis of the Wall Geometry with Different Strategies for High Deposition Wire Arc Additive Manufacturing of Mild Steel(Multidisciplinary Digital Publishing Institute (MDPI), 2020-07) Aldalur, Eider; Veiga, Fernando; Suárez, Alfredo; Bilbao, Jon; Lamikiz, AitzolAdditive manufacturing has gained relevance in recent decades as an alternative to the manufacture of metal parts. Among the additive technologies, those that are classified as Directed Energy Deposition (DED) are characterized by their high deposition rate, noticeably, Wire Arc Additive Manufacturing (WAAM). However, having the inability to produce parts with acceptable final surface quality and high geometric precision is to be considered an important disadvantage in this process. In this paper, different torch trajectory strategies (oscillatory motion and overlap) in the fabrication of low carbon steel walls will be compared using Gas Metal Arc Welding (GMAW)-based WAAM technology. The comparison is done with a study of the mechanical and microstructural characteristics of the produced walls and finally, addressing the productivity obtained utilizing each strategy. The oscillation strategy shows better results, regarding the utilization rate of deposited material and the flatness of the upper surface, this being advantageous for subsequent machining steps.Item Effect of the Heat Input on Wire-Arc Additive Manufacturing of Invar 36 Alloy: Microstructure and Mechanical Properties: Microstructure and Mechanical Properties(2022-04-07) Veiga, Fernando; Suárez, Alfredo; Artaza, Teresa; Aldalur, Eider; Tecnalia Research & Innovation; FABRIC_INTELInvar, also known as FeNi36, is a material of great interest due to its unique properties, which makes it an excellent alterna tive for sectors such as tooling in aeronautics and aerospace. Its manufacture by means of wire arc additive manufacturing (WAAM) technology could extend its use. This paper aims to evaluate the comparison of two of the most widespread WAAM technologies: plasma arc welding (PAW) and gas metal arc welding (GMAW). This comparison is based on the analysis of wall geometry, metallography, and mechanical properties of the material produced by both technologies. The results show a slight increase in toughness and elongation before fracture and worse tensile strength data in the case of PAW, with aver age values of 485 MPa for ultimate tensile strength (UTS), 31% for elongation and 475 MPa, 40% in GMAW and PAW, respectively. All results gathered from the analysis show the possibility of successful manufacturing of Invar by means of WAAM technologies. The novelties presented in this paper allow us to establish relationships between the thermal input of the process itself and the mechanical and metallographic properties of the material produced.Item Effect of the Metal Transfer Mode on the Symmetry of Bead Geometry in WAAM Aluminum(2021-07-10) Veiga, Fernando; Suárez, Alfredo; Aldalur, Eider; Bhujangrao, Trunal; Tecnalia Research & Innovation; FABRIC_INTELThe symmetrical nature in the case of wall fabrication by wire arc additive manufacturing (WAAM) has been observed in the literature, but it has not been studied as a source of knowledge. This paper focuses on the comparative study of three drop transfer methods employing Gas Metal Arc Welding (GMAW) technology, one of the most reported for the manufacture of aluminum alloys. The transfer modes studied are the well-known pulsed GMAW, cold arc, and the newer pulsed AC. The novelty of the last transfer mode is the reversal of the polarity during the preparation phase of the substance for droplet deposition. This study compares the symmetry of zero beads to determine the best parameters and transfer modes for wire arc additive manufacturing of 5 series aluminum. The pulsed transfer modes show values of 0.6 for symmetry ratio, which makes them more interesting strategies than cold arc with a symmetry ratio of 0.5. Furthermore, the methodology proposed in this study can be extrapolated to other materials manufactured with this technology.Item Model for the Prediction of Deformations in the Manufacture of Thin-Walled Parts by Wire Arc Additive Manufacturing Technology(2021-04-21) Casuso, Mikel; Veiga, Fernando; Suárez, Alfredo; Bhujangrao, Trunal; Aldalur, Eider; Artaza, Teresa; Amondarain, Jaime; Lamikiz, Aitzol; FABRIC_INTEL; Tecnalia Research & InnovationGas Metal Arc Welding (GMAW) is a manufacturing technology included within the differentWire 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.Item Study of the Mechanical Behavior of Topologically Optimized Arc Wire Direct Energy Deposition Aerospace Fixtures(2022-02-24) Suárez, Alfredo; Veiga, Fernando; Bhujangrao, Trunal; Aldalur, Eider; FABRIC_INTEL; Tecnalia Research & InnovationThe reliability and performance qualification of additively manufactured metal parts is essential for their successful and safe use in engineering applications. Additive Manufacturing (AM) allows parts to be produced more easily than traditional manufacturing. Arc Wire Direct Energy Deposition (AW-DED) is one of the lesser-known metal additive manufacturing technologies. It has enormous potential for large-scale 3D printing applications in the aerospace industry. However, in the aerospace industry, one of the main challenges today is to reduce the weight of components without compromising their structural functionality. Topology optimization offers design engineers the opportunity to create lightweight and complex structural parts. In arc wire direct energy deposition (AW-DED) processes, processing parameters affect material microstructure features, overall part quality, and integrity, as well as bulk mechanical behavior. To address such challenges, the investigation presented in this paper describes a novel digital design approach combining topology optimization, process simulations, and size optimization of the tool components used in the aerospace industry to address effects caused during manufacturing by using Finite Element Modeling (FEM) simulations. This can lead to reduced costs, development time, material consumption, and product weight. Due to the flexibility mentioned above, parts designed for AM have the same structural load as conventional parts but with reduced mass and better part design. The results of this application are discussed in depth in this paper. This is a new research work with useful results and conclusions in the methodology for the evaluation of mechanical behavior of topologically optimized metal additive manufactured components. For this purpose, aerospace fixtures have been topologically designed by means of AW-DED-process-oriented techniques. Aerospace fixtures are normally used in the aerospace industry to support and hold various components. These new design paradigms make it possible to save on material costs oriented toward more sustainable and flexible manufacturing.Item Validation of the Mechanical Behavior of an Aeronautical Fixing Turret Produced by a Design for Additive Manufacturing (DfAM)(2022-05-27) Veiga, Fernando; Bhujangrao, Trunal; Suárez, Alfredo; Aldalur, Eider; Goenaga, Igor; Gil-Hernandez, Daniel; Tecnalia Research & Innovation; FABRIC_INTEL; MAQUINAS; SMART_MONThe design of parts in such critical sectors as the manufacturing of aeronautical parts is awaiting a paradigm shift due to the introduction of additive manufacturing technologies. The manufacture of parts designed by means of the design-oriented additive manufacturing methodology (DfAM) has acquired great relevance in recent years. One of the major gaps in the application of these technologies is the lack of studies on the mechanical behavior of parts manufactured using this methodology. This paper focuses on the manufacture of a turret for the clamping of parts for the aeronautical industry. The design of the lightened turret by means of geometry optimization, the manufacture of the turret in polylactic acid (PLA) and 5XXX series aluminum alloy by means of Wire Arc Additive Manufacturing (WAAM) technology and the analysis by means of finite element analysis (FEA) with its validation by means of a tensile test are presented. The behavior of the part manufactured with both materials is compared. The conclusion allows to establish which are the limitations of the part manufactured in PLA for its orientation to the final application, whose advantages are its lower weight and cost. This paper is novel as it presents a holistic view that covers the process in an integrated way from the design and manufacture to the behaviour of the component in use