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The purpose of this paper is to verify the performance and function of the scale-up prototypes by predicting the material and energy consumption on the basis of dimension-reduced prototypes. Additive manufacturing (AM) costs determine carbon emissions in total life cycle, among which material and energy consumption are major components. Predicting material and energy consumption is fundamental to reducing costs.

This paper presents a material and energy co-optimization method for AM via multiple layers prediction (MLP). Material and energy consumption are predicted to reduce the AM costs. In particular, scalable, complex curved surface component is used to improve forecasting efficiency. Subsequently, the back pressure distribution is obtained by scale-up specimens, which can lay the foundation for the ergonomic conceptual design.

Taking evolutionary ergonomic product as an example, the relative gravity direction of backrest is calculated. The material and energy consumption are predicted with low deviation. Physical experiments were carried out to validate information. Digital and physical tests have revealed that material and energy co-optimization improves manufacturing efficiency.

The innovatively proposed MLP method predicts material and energy consumption of scale-up prototypes to reduce the costs. It is propitious to improve the carbon emission efficiency in life cycle of AM. The originality may be widely adopted alongside increasing environmental awareness.

Owing to its leverage of high deposition rate, the wire arc additive manufacturing (WAAM) process is being adopted for the development of IN718 alloy used in aerospace, transportation and energy sectors. The purpose of this study is to observe the effect of process parameters on the mechanical properties of the IN718 superalloy.

This study emphasizes the effect of WAAM process parameters on mechanical and metallurgical properties of developed multilayer structures of IN718 alloy by means of orthogonally designed experiments.

The results show that high current and voltage settings, combined with low welding speed, provide increase bead width, height and effective wall area, while resulting in decrease surface waviness, hardness and tensile properties. The scanning electron microscopy and energy dispersive spectroscopy results show the presence of secondary precipitates such as NbC and Ni3(Al, Ti) in low-heat samples, which improve the mechanical properties of the material. However, the presence of Laves phases deteriorates the mechanical properties in high-heat samples. The electron backscatter diffraction results confirmed the presence of more grain boundaries and highly textured surfaces in lower heat samples, which improves mechanical properties.

The effect of process parameters on the microstructural features and mechanical properties along with bead characteristic are studied in-depth and influence of each parameter are discussed.