Advantages and Challenges
Arc-based additive manufacturing offers a number of benefits for industry:
- High deposition rates: The speed of deposition makes the process suitable for making large components
- Cost-effective: This process is typically less expensive than other metal additive manufacturing methods, as well as offering shorter lead times
- Material efficiency: Creates less waste, using materials more effectively than traditional manufacturing methods
Despite the advantages of the process, there are also some challenges:
- Surface finish: Parts created with this process often require post-processing, like machining, to achieve a smooth finish
- Accuracy and precision: This process can provide less precision than others and issues with accuracy, such as stair stepping, can occur
- Defects: Defects such as distortion and porosity can occur unless process parameters are optimise, impacting mechanical properties of the finished part
Wire Arc Additive Manufacturing at TWI
Wire arc additive manufacturing has proven popular due to the ability to produce very near net shape preforms without complex tooling, moulds or dies, which has created significant savings in cost and lead times, increased material efficiency, improved component performance and reduction of inventory and logistics costs from supply chains through local, on-demand manufacture.
The use of high quality computer-aided design and manufacturing (CAD/CAM) has seen this process advance significantly from its beginning in 1920, when it was first patented. As a process it sits between laser-based systems and plasma / electron beam systems when it comes to accuracy and speed.
Our expertise in WAAM systems means that we can provide advice and guidance on the application of arc-based additive manufacturing, including factors ranging from materials to heat input. We can advise on matters such as bead geometries, deposition parameters, residual stresses, surface finishing requirements, and the changing thermal field that occurs as a result of residual heat during the build process.
WAAM has proven to be an effective method for quickly creating parts from materials such as carbon and low alloy steels, stainless steel, nickel-based alloys, titanium alloys and aluminium alloys. TWI has experience in using the process for a range of different industry applications, including for aerospace where it has been shown to reduce time to market.