2023-06-10 15:14:14
By better controlling the current, voltage, gas supply and temperature during the WAAM process, defects can be prevented and the surface quality improves. That is one of the findings of KU Leuven, Thomas Moore Hogeschool, the Belgian Institute for Welding Technology and Sirris.
In the context of the European Ad-Proc-Add (Advanced Processing of Additvely Manufactured Parts) project investigated the influence of various processes within the process chain of additive-subtractive manufacturing. They have developed empirical models for the prediction geometry for both the conventional Gas Metal Arc Welding (GMAW) process and the Cold Metal and for the Cold Metal Transfer (CMT) process.
What steps are needed to achieve better shape and dimensional accuracy?
Dimensional and shape accuracy
One of the aspects the researchers looked at is the step required to achieve dimensional and dimensional and shape accuracy of the part. It was found that the WAAM process parameters have a significant influence on the effective wall width, the surface quality following deposition and the minimum amount of material to be removed during the post-processing step. Another important result concerns the positioning, alignment and optimal cutting parameters of the parts for finishing. Experiments showed that the WAAM process parameters, in particular the speed, wire feed and intermediate temperature, have a significant influence on the characteristics of the deposited surface and the total wall width, which can influence the finishing process – CNC milling.
Sensorplatform
To investigate the influence of the various process parameters, a platform with multiple sensors has been developed. This enabled the Belgian researchers to better monitor both the AM and post-processing steps. Through monitoring of current, voltage, gas flow rate and temperature, the stability of the WAAM process can be evaluated to eliminate various material defects and improve surface performance.
Field tests from the industry
In the final step, which is still ongoing, the researchers will test the findings in concrete cases from various industries. The researchers believe in the potential of WAAM and believe that the research results contribute to improving quality. The research into WAAM is now part of various programs at KU Leuven and Thomas More.
The research took place within the ecoplus Mechatronics cluster in Austria. Here is the final report available from the Forschungskuratorium Maschinenbau (FKM) eV in Germany: [email protected]
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