Browsing by Author "Tabernero, Iván"
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Item Study on Arc Welding Processes for High Deposition Rate Additive Manufacturing(2018) Tabernero, Iván; Paskual, Amagoia; Álvarez, Pedro; Suárez, Alfredo; Ivántabernero; FABRIC_INTELAlthough Additive Manufacturing implementation is rapidly growing, industrial sectors are demanding an increase of manufactured part size which most extended processes, such as Selective Laser Melting (SLM) or Laser Metal Deposition (LMD), are not able to offer. In this sense, Wire-Arc Additive Manufacturing (WAAM) offers high deposition rates and quality without size limits, becoming the best alternative for additive manufacturing of medium-large size parts with high mechanical requirements such as structural parts in the aeronautical industry. WAAM technology adds material in form of wire using an arc welding process in order to melt both the wire and the substrate. There are three welding processes that are mainly used in WAAM: Plasma Arc Welding (PAW), Gas Tungsten Arc Welding (GTAW or TIG) and Gas Metal Arc Welding (GMAW or MIG). This paper studies these processes regarding on their capabilities for additive manufacturing and compares the mechanical properties obtained by the different welding technologies applied in WAAM. Obtained results show the applicability of the technology as an alternative of traditional metallic preforms manufacturing processes, such as casting or forging.Item Wire arc additive manufacturing of an aeronautic fitting with different metal alloys: From the design to the part(2021-04) Suárez, Alfredo; Aldalur, Eider; Veiga, Fernando; Artaza, Teresa; Tabernero, Iván; Lamikiz, Aitzol; FABRIC_INTEL; Tecnalia Research & InnovationWAAM (Wire Arc Additive Manufacturing), an additive manufacturing technology with high deposition rates, can produce metallic components, layer by layer, from different alloys, yielding high mechanical performance. Customized AM machines with monitoring and control systems are necessary to facilitate automated manufacture of different types of components through WAAM technology. In this paper, a methodology for the validation of additive manufacturing is presented as an alternative to industrial machining, for the manufacture of medium-sized aeronautical parts. To begin with, the most appropriate welding technology and adequate parameters for four different metal alloys are selected. Successively, a characterization wall is manufactured with each of the four metal alloys, for metallographic and mechanical characterization, concluding that the material deposited utilizing the WAAM process is adequate for the fabrication of medium-sized aeronautical parts. Consecutively, machine paths are defined under conditions that consume the least possible amount of material for the manufacturing of the aeronautical part. Several aspects -manufacturing times, deposition rate, material efficiency ratio- of each component are then analyzed, relating them to the properties obtained in each alloy. The manufacturing process is supervised and controlled by online monitoring. The novelty of this paper consists in establishing unique dataset for each component that is defined as a unique additive manufacturing Fingerprint as baseline for in process defect detection. Finally, the unique contribution of stablishing a matrix-strategy for the manufacture of multiple parts with the same tooling to optimize the use of resources is presented.Item Wire arc additive manufacturing of Mn4Ni2CrMo steel: Comparison of mechanical and metallographic properties of PAW and GMAW(2019) Artaza, Teresa; Suárez, Alfredo; Murua, Maialen; García, J. C.; Tabernero, Iván; Lamikiz, Aitzol; FABRIC_INTEL; FACTORY; CIRMETALWire arc additive manufacturing, WAAM, is a popular wire-feed additive manufacturing technology that creates components through the deposition of material layer-by-layer. WAAM has become a promising alternative to conventional machining due to its high deposition rate, environmental friendliness and cost competitiveness. In this research work, a comparison is made between two different WAAM technologies, GMAW (gas metal arc welding) and PAW (plasma arc welding). Comparative between processes is centered in the main variations while manufacturing Mn4Ni2CrMo steel walls concerning geometry and process parameters maintaining the same deposition ratio as well as the mechanical and metallographic properties obtained in the walls with both processes, in which the applied energy is significantly different. This study shows that acceptable mechanical characteristics are obtained in both processes compared to the corresponding forging standard for the tested material, values are 23% higher for UTS and 56% for elongation in vertical direction in the PAW process compared to GMAW (no differences in UTS and elongation results for horizontal direction and in Charpy for both directions) and without significant directional effects of the additive manufacturing technology used.Item Wire Arc Additive Manufacturing of Mn4Ni2CrMo Steel: Comparison of Mechanical and Metallographic Properties of PAW and GMAW(2019) Artaza, Teresa; Suárez, Alfredo; Murua, Maialen; García, J.C.; Tabernero, Iván; Lamikiz, Aitzol; FABRIC_INTEL; FACTORYWire arc additive manufacturing, WAAM, is a popular wire-feed additive manufacturing technology that creates components through the deposition of material layer-by-layer. WAAM has become a promising alternative to conventional machining due to its high deposition rate, environmental friendliness and cost competitiveness. In this research work, a comparison is made between two different WAAM technologies, GMAW (gas metal arc welding) and PAW (plasma arc welding). Comparative between processes is centered in the main variations while manufacturing Mn4Ni2CrMo steel walls concerning geometry and process parameters maintaining the same deposition ratio as well as the mechanical and metallographic properties obtained in the walls with both processes, in which the applied energy is significantly different. This study shows that acceptable mechanical characteristics are obtained in both processes compared to the corresponding forging standard for the tested material, values are 23% higher for UTS and 56% for elongation in vertical direction in the PAW process compared to GMAW (no differences in UTS and elongation results for horizontal direction and in Charpy for both directions) and without significant directional effects of the additive manufacturing technology used.Item Wire arc additive manufacturing Ti6Al4V aeronautical parts using plasma arc welding: Analysis of heat-treatment processes in different atmospheres(2020) Artaza, Teresa; Suárez, Alfredo; Veiga, Fernando; Braceras, Inigo; Tabernero, Iván; Larrañaga, Oihane; Lamikiz, Aitzol; FABRIC_INTEL; Tecnalia Research & Innovation; INGENIERÍA DE SUPERFICIESPAW (Plasma Arc Welding), a WAAM (Wire Arc Additive Manufacturing) technology with high deposition rates, can produce metallic components, layer by layer, of varied sizes, from different alloys, yielding high mechanical performance. Two Ti6Al4V walls are manufactured in an inert argon atmosphere using WAAM-PAW to analyze the deposition process in terms of growth in height per layer, deposition process temperature, and cooling times. The properties of the walls are compared with the values obtained from a thermomechanical simulation and both the microstructural and mechanical properties of the annealed WAAM-PAW wall are studied. Moreover, the effect of the media on the oxidation layer and on the mechanical properties are also analyzed throughout the heat treatment process, as well as the microstructure of Ti6Al4V. Stable deposition rates were achieved for a high deposition ratio of Ti6Al4V at 2 kg/h, restricting the oxygen levels to under 100 ppm. No significant differences were found in either the microstructural or the mechanical properties following heat treatments in a vacuum, in air or in argon. All the heat-treated samples met the AMS4928 standard for Yield Strength (YS) and Ultimate Tensile Strength (UTS).