TWI Industrial Member Report Summary 1087/2017
By Anita Ward and Nick Bagshaw
Wire-fed electron beam additive manufacturing (W-EBAM) and other wire additive processes enable a large volume of material to be deposited rapidly, but require a final machining operation to reach final dimensional tolerances. The aerospace community is focussing on these high deposition rate technologies, in a drive to reduce material usage and scrap. However, in order for W-EBAM to provide an industrially viable solution, distortion issues require control.
Type the Key Findings of this project here – use the Content Text KFI Style, up to 6 bullets demonstrating the value of this project to Industrial Members
- W-EBAM deposits of up to 50mm have been built in Ti-6Al-4V at a rate of 0.5kg/hr.
- A stiffening effect is observed as the height of the deposit increases; however, the rolling direction does not have a significant effect on the distortion of the plate.
- An FEA model of distortion in the W-EBAM process has been developed and validated and used to investigate distortion mitigation strategies. Preheating the substrate provides the best benefit – 45% reduction in distortion.
- Improvements in processing quality were achieved through reducing the processing power as the build height increased.
- A demonstrator aerospace wing rib post was fabricated to promote the process and a zircaloy deposit was made to show the potential for power sector applications.
- Basic calculations suggest a 40% reduction in cost over machining from solid.