Model for the Prediction of Deformations in the Manufacture of Thin-Walled Parts by Wire Arc Additive Manufacturing Technology

• Published in: Metals (Basel ) Vol. 11; no. 5; p. 678
• Main Authors: Casuso, Mikel, Veiga, Fernando, Suárez, Alfredo, Bhujangrao, Trunal, Aldalur, Eider, Artaza, Teresa, Amondarain, Jaime, Lamikiz, Aitzol
• Format: Journal Article
• Language: English
• Published: Basel MDPI AG 01.05.2021
• Subjects: Adaptation; Additive manufacturing; Deformation; Finite element method; Gas metal arc welding; Heat; Mathematical models; Mechanical properties; Near net shaping; process modelling; Residual stress; Simulation; Software; thin wall manufacturing; Wire; France; United States > US; Germany
• ISSN: 2075-4701; 2075-4701
• DOI: 10.3390/met11050678

Gas Metal Arc Welding (GMAW) is a manufacturing technology included within the different Wire Arc Additive Manufacturing alternatives. These technologies have been generating great attention among scientists in recent decades. Its main qualities that make it highly productive with a large use of material with relatively inexpensive machine solutions make it a very advantageous technology. This paper covers the application of this technology for the manufacture of thin-walled parts. A finite element model is presented for estimating the deformations in this type of parts. This paper presents a simulation model that predicts temperatures with less than 5% error and deformations of the final part that, although quantitatively has errors of 20%, qualitatively allows to know the deformation modes of the part. Knowing the part areas subject to greater deformation may allow the future adaptation of deposition strategies or redesigns for their adaptation. These models are very useful both at a scientific and industrial level since when we find ourselves with a technology oriented to Near Net Shape (NNS) manufacturing where deformations are critical for obtaining the final part in a quality regime.