Wire and arc additive manufacturing of metal components: a review of recent research developments
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ORIGINAL ARTICLE
Wire and arc additive manufacturing of metal components: a review of recent research developments Jienan Liu 1 & Yanling Xu 1,2 & Yu Ge 1 & Zhen Hou 1 & Shanben Chen 1,2 Received: 12 April 2020 / Accepted: 17 August 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract Wire arc additive manufacturing (WAAM) is an important metal 3D printing method, which has many advantages, such as rapid deposition rate, low cost, and suitability for large complex metal components manufacturing, and it has received extensive attention. This paper summarizes the research developments of WAAM in recent years, including the WAAM-suitable metal materials and processing technology, deposition strategy optimization including slicing and path planning algorithm, multisensor monitoring and intelligent control, and the large complex metal components manufacturing technology. The promising development directions of WAAM are prospected, including the research of new materials and new technology, composite manufacturing, multi-sensor and real-time monitoring, algorithmic optimization of metal filling strategy, and the application of artificial intelligence technology in WAAM, etc. Keywords WAAM . Weldability . Slicing algorithm . Path planning . Multi-sensor . Intelligent control . Large complex metal components manufacturing
1 Introduction Due to the advantages of design flexibility, low manufacturing cost, and possibility to use almost all kinds of raw materials such as polymers, metals, concrete, and ceramics, 3D printing is still a hot issue of research after 30 years of development; it has received extensive attention in the fields of biomedicine, aerospace, art esthetics, and architectural design [1]. Especially the high-performance 3D printing technology of metal is widely regarded as the most difficult and promising frontier development direction in the industry, and it is also the most direct forming technology that can serve the equipment manufacturing industry. Metal 3D printing produces fully dense, high-precision metal parts in a short period of time,
* Yanling Xu [email protected]; [email protected] 1
Intelligentized Robotic Welding Technology Laboratory, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, People’s Republic of China
2
Shanghai Key Laboratory of Materials Laser Processing and Modification, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, People’s Republic of China
and is designed for freedom and for complex components, lightweight, customized, which can be directly applied to aerospace, oil and gas, and marine and automotive applications [2]. As shown in Fig. 1, there are currently four main methods for metal additive manufacturing; especially powder bed fusion (PBF) and directed energy deposition (DED) are the main forms of metal additive manufacturing included in ISO/ASTM 52900 [3]. PBF is a method of additive manufacturing in which material within a powder bed is selectively fuse
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