Investigation of complex single-walled intersecting structures fabricated by wire-arc directed energy deposition
ISSN: 1355-2546
Article publication date: 9 August 2024
Issue publication date: 27 August 2024
Abstract
Purpose
This study aims to investigate an intersecting single-walled structure fabricated using wire-arc directed energy deposition (waDED). Because of the highly complex geometrical features of this structure, characterisation is used to identify potential weak points and provide a benchmark for future complex components.
Design/methodology/approach
A structural component with a process-specific design is built using additive manufacturing of an Al-Mg alloy and analysed using micro-computed tomography. Scans are carried out at different resolutions and subsequently compared to microsections. The chemical composition and hardness are also examined. These investigations provide an enhanced understanding of defects and overall quality of the manufactured parts.
Findings
The results show that very high-quality parts can be achieved using ER5183 alloy, even in intersecting areas. Defects in these regions are primarily caused by converging and diverging waDED paths and discontinuous waDED operations.
Originality/value
In addition to demonstrating the feasibility of complex structures using waDED, this study provides an overview of problem areas and potential improvements in waDED manufacturing.
Keywords
Acknowledgements
This research received funding from the project “DEDAluS – Directed Energy Deposition of Aluminium Structures” (grant agreement no. 877340) funded by the Austrian Federal Ministry for Climate Action, Environment, Energy, Mobility, Innovation and Technology (BMK) administered by Austrian Funding Agency (FFG) within the framework “Production of the Future”. The authors would like to thank the project partners AMAG casting, MIGAL.CO, RHP-Technology and Alcar Wheels for collaborative pursuit of this project; and “We3D – Wire-based additive manufacturing – materials and technologies – for 3D metal structures of the future” (grant agreement no. 886184) funded by the federal ministry of Climate Action, Environment, Energy, Mobility, Innovation and Technology (BMK), the Ministry of Digital and Economic Affairs (BMDW), as well as the four federal funding agencies Amt der Oberösterreichischen Landesregierung; Steirische Wirtschaftsförderungsgesellschaft m.b.H.; Amt der Niederösterreichischen Landesregierung; Wirtschaftsagentur Wien; and Ein Fonds der Stadt Wien administered by the FFG in the framework of the Eighth COMET call. The authors also thank the industry partners for their financial and research contributions to the five multi-firm projects. The authors sincerely thank M. Schnall for his expert contribution and valuable discussions.
Citation
Silmbroth, M., Enzinger, N., Senck, S., Radlmayr, K. and Klein, T. (2024), "Investigation of complex single-walled intersecting structures fabricated by wire-arc directed energy deposition", Rapid Prototyping Journal, Vol. 30 No. 8, pp. 1707-1716. https://doi.org/10.1108/RPJ-10-2023-0345
Publisher
:Emerald Publishing Limited
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