ROBOTIC WIRE ARC ADDITIVE MANUFACTURING OF · PDF fileCOST CRM-EXTREME, 16.6.2017, Prague,...

COST CRM-EXTREME, 16.6.2017, Prague, Czech Republic

ROBOTIC WIRE ARC ADDITIVE MANUFACTURING OF METAL PRODUCTS

Damjan Klobčar1, Janez Tušek1, Maja Lindič 1, Boris Bell 2

1 Faculty of Mechanical Engineering, University of Ljubljana, Aškerčeva 6, 1000 Ljubljana, Slovenia;

e-mail: [email protected] School center Postojna, Cesta v Staro vas 2, 6230 Postojna, Slovenia

University of LjubljanaFakulteta za strojništvoLaboratorij za varjenje

mailto:[email protected]

D. Klobčar et al. Robotic WAAM of metal products COST CRM-EXTREME, 16.6.2017, Prague, Czech Republic

University of LjubljanaFaculty of Mechanical

EngineeringWelding Laboratory

INTRODUCTION




AM technologies




Comparison of different AM technologies




Advantages and disadvantages of AM technologies

10

10

10

10

1010

10

10

10

Build rate

Complexity

Accuracy

Cost savings

Material utilisationMech. properties

Post-processing requirement

Platform flexibility

Part size

Powder-bed

Blown-powder

WAAM

Hi. Dep. Wire-fed




History of WAAM

• 1926 Baker – patent of electric arc as heat source for deposition of melted material to manufacture 3D object

• 1971 Ujiie (Mitsubishi) – manufacturing of pressure valve with SAW, ESW and TIG welding – multi wire and multi materials.

• 1983 Kussmaul – shape welding of large and high quality nuclear construction parts from 20MnMoNi5 steel (build rate 80 kg/h, mass 79 ton).

• 1993 Prinz, Weiss – patent of hybrid CNC machine for welding and milling – „Shape Deposition Manufacturing“

• 1994-1999 Cranfield University – development of „Shape Metal Deposition“ process for manufacturing of castings for aircraft engines for Rolls Royce.

• H2020–FoF-2016- 723917-OPENHYBRID from CAD to production with advanced all-in-one machineshttp://www.ewf.be/news/openhybrid-kom.aspx .

http://www.ewf.be/news/openhybrid-kom.aspx




Materials and products

Titaniumalloys

Aluminumalloys

Tool steel Other alloys Stainless steel Temperature resistant

Ti-6Al-4V Al-Si-Mg H13 IN625 316 & 316L MoRe

ELI Ti 6061 IN718 420 Ta-W

CP Ti 347 CoCr

γ-TiAl PH 17-4

Usually used material for Additive Manufacturing

0.8 metre tall aluminium/steelconics built for Lockheed Martin

2.5 metre x 1.2 metre aluminium wing

rib for Bombardier

1 metre tallturbine blade (steel)

Projectiles

Dissimilar part Steel/bronze (CuSi3%)




Samples from our laboratory




Materials – Steel, Titanium, Aluminium

Mass[kg]

BTF Cost [k₤]

Costred.

SteelOriginal, machined 36 12 1.6 -

Original, WAAM 36 2.3 0.7 55%

TitaniumOriginal, machined 20 12 16.2 -

Original, WAAM 20 2.3 5 69%

Aircraft landing gear

Design options (MRR =[323 kg/h])

BTF Cost [k₤]

Costred.

Machined from solid 45 4.4 -

WAAM, option 1 2.9 1.7 61%

WAAM, option 2 12.3 1.9 56%

Buy – to – Fly = efficiency of fedstock material= Vfeedstock/ Vproduct

Aircraft wing structure




EXPERIMENTAL PART

D. Klobčar, … 3D tiskanje kovinskih…. DVT in DNVT 2016, IZV, Ljubljana, Slovenija, 2.11.2016

Determination of parameters for stable WAAM process – thin walls

• Welding power source: FroniusTransPuls Synergic 3200 CMT R

• Welding robot: ABB IRB 140-6/0.8

• Temperature measurement: VOLTCRAFT M – 3850

• Base metal: S335 dimension: 100x25x8 mm

• Filler wire: G3Si1 (VAC 60)• Shielding gas: CO2, CORGON 18,

Ar • Gas flow: 10 l/min

• Parametric analysis (I = 40, 90, 140 A, wspeed = 3, 7.5, 12 mm/s) – standard,

CMT and pulse welding control,

• Welding in positions:

PA, PC and PG

•Analysis (tensile test, hardness measurement, metallographic analysis).

• Manufacturing of final part (CAD + SprutCAM – path programing).




RESULTS

STANDARD PULS CMT

Optimization of welding parameters




Wavy surface

Process optimization

• Eliminate wavy surface with optimization of heat input

Alternating directionSlope - Welding to one side

(I=90 A , v=7,5 mm/s)

0

5

10

15

20

25

0 20 40 60 80 100 120 140 160

Vo

ltag

e-

U [

V]

Welding current - I [A]

CMT

CMT+PULZ

1. Optimisaiton 2. Optimisation

• Eliminate the slope with alternately changing welding direction and control of interpass temperature




Optimization of process parameters -CMT+PULS

I=59 A, v=5 mm/s, Q=103,8 kJ/m I=141 A, v=7,5 mm/s, Q=419,2 kJ/mI=90 A, v=7,5 mm/s, Q=244,8 kJ/m

0,5

1

1,5

2

2,5

3

2 3 4 5 6 7 8 9 10 11 12 13

Laye

rh

eigh

t[m

m]

Welding speed [mm/s]

I = 40 A (hladno varjen)

I = 40 A ( povp. navarjene stene -medvarkovna tem. 200 °C)

1

2

3

4

5

2 3 4 5 6 7 8 9 10 11 12 13La

yer

wid

th[m

m]

Welding speed [mm/s]

40 A (cold welding)

40 A (average interpass

temperature 200 °C)



EngineeringWelding Laboratory a) I = 40 A, v = 5 mm/s

b) I = 90 A, v = 7,5 mm/sc) I = 140 A, v = 7,5 mm/s

Higher energy input -> wider and higher weld deposit.

a) b) c)PA

I = 40 A, v = 5 mm/s

Lower energy input -> preventing of excessive melting.

I = 90 A, v = 7,5 mm/s

Lower energy input -> holding the melt at end of weld.

PG

PC

Successful welding in different welding positions




Tensile strength of deposit is lower than the filler metal

0

0,2

0,4

0,6

0,8

1

1,2

0 2 4 6

Forc

e[k

N]

Elongation [mm]

0

0,2

0,4

0,6

0,8

1

1,2

0 1 2 3 4 5

Forc

e[k

N]

Elongation [mm]

0

0,2

0,4

0,6

0,8

1

1,2

1,4

0 1 2 3 4

Forc

e[k

N]

Elongation [mm]

a)

b)

c)

45° Angle

90° Angle

0° Angle

An

gle

[°]

The filler metal: Rm = 500 – 640 MPa




WAAM of tube welded at I = 59 A, v = 5 mm/s




How to affect the

use of CRM

Potential use of the technology

- To produce the tools with increased lifetime.

- Multimaterialcomponents




Project proposalThe use of additive manufacturing to increase

the lifetime of industrial tooling




CONCLUSIONS

A parametric analysis of WAAM using MIG/MAG welding for production of thin wall structures was done.

• An optimally low heat input during weld deposition (100-300 kJ/m) must be done in order to make stable deposition of layer dimensions. At < 100 kJ/m wavy weld deposition; at > 300 kJ/m melting of material.

• It is important to control the weld interpass temperature. It should not exceed 100 °C.

• An optimal process to control was achieved by combination of CMT and pulsed welding.

• Welding in different welding position is possible; the easiest welding is done in PA position. When welding in other positions we must consider the gravity, weld interpass temperature, and energy input.



EngineeringWelding Laboratory THANK YOU FOR ATTENTION

We are open for collaboration ([email protected])

Acknowledgment

The work was partly sponsored by EU European Regional Development Fund and Ministry of Education,

Science and Sport of the Republic of Slovenia under the Strategy of Smart Specialisation Project MARTINA

(MAteRials and TehnologIes for New Aplications) http://www.martina-eu.net/si/ .

The work was partly sponsored by EU European Social Found, Ministry of Education, Science and Sport of the

Republic of Slovenia and Slovene human resources development and scholarship fund under the project name

„Robotic weld surfacing“.

http://www.martina-eu.net/si/

ROBOTIC WIRE ARC ADDITIVE MANUFACTURING OF · PDF fileCOST CRM-EXTREME, 16.6.2017, Prague,...

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