Browsing by Keyword "WAAM"
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Item Analysis of the Machining Process of Titanium Ti6Al-4V Parts Manufactured by Wire Arc Additive Manufacturing (WAAM)(2020-02-01) Veiga, Fernando; Gil Del Val, Alain; Suárez, Alfredo; Alonso, Unai; Tecnalia Research & Innovation; FABRIC_INTELIn the current days, the new range of machine tools allows the production of titanium alloy parts for the aeronautical sector through additive technologies. The quality of the materials produced is being studied extensively by the research community. This new manufacturing paradigm also opens important challenges such as the definition and analysis of the optimal strategies for finishing-oriented machining in this type of part. Researchers in both materials and manufacturing processes are making numerous advances in this field. This article discusses the analysis of the production and subsequent machining in the quality of TI6Al4V produced by Wire Arc Additive Manufacturing (WAAM), more specifically Plasma Arc Welding (PAW). The promising results observed make it a viable alternative to traditional manufacturing methods.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 Characterization of Inconel 718® superalloy fabricated by wire Arc Additive Manufacturing: effect on mechanical properties and machinability: effect on mechanical properties and machinability(2021-09) Alonso, Unai; Veiga, Fernando; Suárez, Alfredo; Gil Del Val, Alain; Tecnalia Research & Innovation; FABRIC_INTELWire and Arc Additive Manufacturing has the potential to become an appropriate technique to produce large complex-shaped metallic parts. However, a post-processing machining operation is necessary to reach the final geometry. In this work, Inconel 718 walls were manufactured in a monitored environment and their microstructure and mechanical properties were characterised. Then, slot milling operations were performed to investigate the influence of cutting speed and machining direction. The conclusions drawn from this article can be used as a guide for a correct definition of strategies and milling parameters. It was observed that at higher cutting speeds a better surface quality and lower torques are obtained. Moreover, the main novelty of this work is that is shows the influence of the anisotropy of WAAM-Inconel 718 on its machinability. Milling along the torch's travel direction offers better dimensional tolerance values with lower cutting torques, being more favourable than machining in the building direction.Item Design and integration of WAAM technology and in situ monitoring system in a gantry machine(2017) Artaza, T.; Alberdi, A.; Murua, M.; Gorrotxategi, J.; Frías, J.; Puertas, G.; Melchor, M.A.; Mugica, D.; Suárez, A.; FABRIC_INTEL; FACTORY; ROBOTICA_AUTOMA; Tecnalia Research & Innovation; VISUALWire 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, an adaptation of a gantry machine with in-situ monitoring and a control system has been carried out, in order to expose the ability of the WAAM technology to fabricate complex-shaped parts. The retrofitting of the machine has been done in several layers called respectively hardware, control and software layers. For the validation of the implemented system, a stainless steel 316L demonstrator has been manufactured, and the required stages have been employed, including part design (CAD), process parameters selection, tool-path definition (CAM) and part manufacturing. This study has shown the feasibility of the adapted machine for additive manufacturing as a controlled process.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 Experimental Investigation of the Influence of Wire Arc Additive Manufacturing on the Machinability of Titanium Parts(2020-01) Alonso, Unai; Veiga, Fernando; Suárez, Alfredo; Artaza, Teresa; Tecnalia Research & Innovation; FABRIC_INTELThe manufacturing of titanium airframe parts involves significant machining and low buy-to-fly ratios. Production costs could be greatly reduced by the combination of an additive manufacturing (AM) process followed by a finishing machining operation. Among the different AM alternatives, wire arc additive manufacturing (WAAM) offers deposition rates of kg/h and could be the key for the production of parts of several meters economically. In this study, the influence of the manufacturing process of Ti6Al4V alloy on both its material properties and machinability is investigated. First, the mechanical properties of a workpiece obtained by WAAM were compared to those in a conventional laminated plate. Then, drilling tests were carried out in both materials. The results showed that WAAM leads to a higher hardness than laminated Ti6Al4V and satisfies the requirements of the standard in terms of mechanical properties. As a consequence, higher cutting forces, shorter chips, and lower burr height were observed for the workpieces produced by AM. Furthermore, a metallographic analysis of the chip cross-sectional area also showed that a serrated chip formation is also present during drilling of Ti6Al4V produced by WAAM. The gathered information can be used to improve the competitiveness of the manufacturing of aircraft structures in terms of production time and cost.Item Influence of Heat Input on the Formation of Laves Phases and Hot Cracking in Plasma Arc Welding (PAW) Additive Manufacturing of Inconel 718(2020-06) Artaza, Teresa; Bhujangrao, Trunal; Suárez, Alfredo; Veiga, Fernando; Lamikiz, Aitzol; FABRIC_INTEL; Tecnalia Research & InnovationNickel-based alloys have had extensive immersion in the manufacturing world in recent decades, especially in high added value sectors such as the aeronautical sector. Inconel 718 is the most widespread in terms of implantation. Therefore, the interest in adapting the manufacture of this material to additive manufacturing technologies is a significant objective within the scientific community. Among these technologies for the manufacture of parts by material deposition, plasma arc welding (PAW) has advantages derived from its simplicity for automation and integration on the work floor with high deposition ratios. These characteristics make it very economically appetizing. However, given the tendency of this material to form precipitates in its microstructure, its manufacturing by additive methods is very challenging. In this article, three deposition conditions are analyzed in which the energy and deposition ratio used are varied, and two cooling strategies are studied. The interpass cooling strategy (ICS) in which a fixed time is expected between passes and controlled overlay strategy (COS) in which the temperature at which the next welding pass starts is controlled. This COS strategy turns out to be advantageous from the point of view of the manufacturing time, but the deposition conditions must be correctly defined to avoid the formation of Laves phases and hot cracking in the final workpiece.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 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 useItem Wire Arc Additive Manufacturing of Mn4Ni2CrMo Steel: Comparison of Mechanical and Metallographic Properties of PAW and GMAW(Elsevier B.V., 2019) Artaza, Teresa; Suárez, Alfredo; Murua, Maialen; García, J.C.; Tabernero, Iván; Lamikiz, AitzolWire 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.