Effect of process parameters during wire arc additive manufacturing (WAAM) and mechanical finishing on the surface zone properties

authored by: Berend Denkena, Marcel Wichmann, Philipp Pillkahn
Abstract: Additive manufacturing processes for the production of large structural components, such as wire arc additive manufacturing (WAAM), offer great manufacturing potential due to their flexibility and design freedom, e.g. for the automotive industry. In order to achieve the desired surface and properties of the surface zone, additive manufacturing is usually followed by mechanical finishing. In this paper, the influence of the process parameters during WAAM and deep rolling (DR) on the residual stresses and the lifetime of AlSi12 components is investigated. Knowledge of the interactions between the process parameters in WAAM and DR as well as their effect on the surface zone properties and the application behavior is elementary. This enables the prediction of the component properties and quality. With the help of the appropriate selection of the process parameters, the residual stress state and the service life can be increased in such a way that components with high fatigue strength can be manufactured. This results in an average increase in service life of up to 17.8 times.
Organisation(s): Institute of Production Engineering and Machine Tools
Type: Conference article
Journal: Procedia CIRP
Volume: 123
Pages: 262-267
No. of pages: 6
ISSN: 2212-8271
Publication date: 2024
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: Control and Systems Engineering, Industrial and Manufacturing Engineering
Electronic version(s): https://doi.org/10.1016/j.procir.2024.05.047 (Access: Open)

BibTeX

@article{6fba1889b10d4cf199432e510f05d902,
title = "Effect of process parameters during wire arc additive manufacturing (WAAM) and mechanical finishing on the surface zone properties",
abstract = "Additive manufacturing processes for the production of large structural components, such as wire arc additive manufacturing (WAAM), offer great manufacturing potential due to their flexibility and design freedom, e.g. for the automotive industry. In order to achieve the desired surface and properties of the surface zone, additive manufacturing is usually followed by mechanical finishing. In this paper, the influence of the process parameters during WAAM and deep rolling (DR) on the residual stresses and the lifetime of AlSi12 components is investigated. Knowledge of the interactions between the process parameters in WAAM and DR as well as their effect on the surface zone properties and the application behavior is elementary. This enables the prediction of the component properties and quality. With the help of the appropriate selection of the process parameters, the residual stress state and the service life can be increased in such a way that components with high fatigue strength can be manufactured. This results in an average increase in service life of up to 17.8 times.",
keywords = "additive manufacturing, durability, residual stresses",
author = "Berend Denkena and Marcel Wichmann and Philipp Pillkahn",
note = "Publisher Copyright: {\textcopyright} 2024 The Authors. Published by Elsevier B.V.; 7th CIRP Conference on Surface Integrity, CSI 2024 ; Conference date: 15-05-2024 Through 17-05-2024",
year = "2024",
doi = "10.1016/j.procir.2024.05.047",
language = "English",
volume = "123",
pages = "262--267",
journal = "Procedia CIRP",
issn = "2212-8271",
publisher = "Elsevier BV",
}