Effect of stepover and torch tilting angle on a repair process using WAAM

Francesco Baffa; Giuseppe Venturini; Gianni Campatelli; Emanuele Galvanetto

doi:10.1007/s40436-022-00393-2

Advances in Manufacturing ›› 2022, Vol. 10 ›› Issue (4) : 541 -555. DOI: 10.1007/s40436-022-00393-2

Article

Effect of stepover and torch tilting angle on a repair process using WAAM

Author information +

¹ Department of Industrial Engineering, University of Florence, Florence, Italy

^a francesco.baffa@unifi.it

Francesco Baffa is a PhD student at the Manufacturing Technologies Research Laboratory (MTRL) of the department of industrial engineer of Florence. His main research topic are remanufacturing processes through WAAM-based hybrid technologies (Subtractive+Additive Manufacturing).

[graphic not available: see fulltext]

Giuseppe Venturini graduated from the University of Florence in October 2014. In 2018 he achieved a PhD in Industrial Engineering at the University of Florence. He is a mechanical engineer dedicated to CAM (Computer Aided Additive Manufacturing) development for Direct Energy Deposition Additive Manufacturing Technologies. He actively researches in algorithm implementation using C++ programming language to improve the generation and the performance of deposition toolpath for Additive Manufacturing applied to the repair of worn or damaged metallic components. Moreover, he is dedicated to experimental testing of the developed deposition toolpaths, in particular with the WAAM technology (Wire and Arc Additive Manufacturing). He is also involved in graphical user interface development in C++. He started collaborating with the MTRL (Mechanical Technology Research Laboratory) of the University of Florence in 2015 and he is currently a post-doctoral fellow at that Laboratory.

[graphic not available: see fulltext]

Gianni Campatelli is an associate professor of manufacturing technologies at the University of Florence. His main interests are additive manufacturing of metals and machining processes; he believes that the integration of these technologies could lead to new manufacturing solutions, particularly interesting for repairing and implementing greener manufacturing strategies. He led many National and EC projects as local and global coordinator. Last project is RetroFix (www.retrofix-project.net).

[graphic not available: see fulltext]

Emanuele Galvanetto is associate professor of Materials Science and Technology at the University of Florence, Dept. of Industrial Engineering (DIEF). His research activity is focused mainly on surface modification of metallic materials by production and characterization of coatings using several advanced technologies (plasma discharge and PACVD). The research topics have been addressed in the field of surface engineering by producing and studying thin and thick film coating (PVD, CVD and Plasma Spray) and surface modified layers (Glow Discharge). He therefore has more than twenty years of experience in the field of film production, surface modification treatments and in their microstructural (microscopy and X-ray techniques) and functional characterization (wear and corrosion behavior). He was involved in many international (European) and national research projects and he has been scientific investigator of research programs committed by relevant local and national industrial partners. He is member of the Research Unit of Florence of the National Interuniversity Consortium of Materials Science and Technology (INSTM) and Coordinator of Materials Characterization Laboratory (MatchLab) of the University of Florence. Research interests: surface modification, film fabrication, surface characterization, wear, and corrosion.

[graphic not available: see fulltext]

Show less

History +

PDF

Abstract

To sustain the transition to a greener economy and greener manufacturing, it is necessary to develop new approaches and technologies to repair metal components; this will result in a drastic reduction in energy and material usage. In this study, wire arc additive manufacturing (WAAM) was used to deposit a layer of new material on an existing surface, with the objective of finding the optimal configuration that maximized the layer quality and material efficiency. The parameters considered are the stepover among the deposited beads and the inclination of the torch with respect to the repaired surfaces. The inclination angle is crucial when repairing complex surfaces, like those of a mold, owing to accessibility issues, the torch cannot be maintained orthogonal to the surfaces along the entire toolpath. Different configurations were tested in order to assess the quality of the materials in terms of the presence of material voids, depth of penetration, and the heat affected zone (HAZ) and to understand the effects of these variables on the material efficiency and thickness of the repairing layer. It should be noted that by adopting deposition parameters set to have a low heat input, the use of a tilting angle has beneficial effects on the quality of the deposited layer and the process efficiency. Metallurgical and geometrical measurements were carried out to assess the effect of these two variables depositing a layer of plain carbon steel.

Keywords

Wire arc additive manufacturing (WAAM) / Repairing· Torch inclination / Stepover / Remanufacturing

Cite this article

Download citation ▾

Francesco Baffa, Giuseppe Venturini, Gianni Campatelli, Emanuele Galvanetto. Effect of stepover and torch tilting angle on a repair process using WAAM. Advances in Manufacturing, 2022, 10(4): 541-555 DOI:10.1007/s40436-022-00393-2

登录浏览全文

4963

注册一个新账户忘记密码

References

Publishing order | Descend order by publishing year | Descend order by cited within

[1]	European Commission (2011) Roadmap to a resource efficient Europe, Brussels

[2]	European Commission (2020) Circular economy action plan. Eur Comm, March, p 28

[3]	Eurometaux (2016) EU circular economy package—overall recommendations, April

[4]	Aziz NA, Adnan NAA, Wahab DA, et al. Component design optimisation based on artificial intelligence in support of additive manufacturing repair and restoration: current status and future outlook for remanufacturing. J Clean Prod, 2021, 296: 126401.

[5]	Liao H, Li C, Nie Y, et al. Environmental efficiency assessment for remanufacture of end of life machine and multi-objective optimization under carbon trading mechanism. J Clean Prod, 2021, 308: 127168.

[6]	Acharya R, Das S. Additive manufacturing of IN100 superalloy through scanning laser epitaxy for turbine engine hot-section component repair: process development, modeling, microstructural characterization, and process control. Metall Mater Trans A Phys Metall Mater Sci, 2015, 46(9): 3864-3875.

[7]	Liu Q, Janardhana M, Hinton B, et al. Laser cladding as a potential repair technology for damaged aircraft components. Int J Struct Integr, 2011, 2(3): 314-331.

[8]	Wilson JM, Piya C, Shin YC, et al. Remanufacturing of turbine blades by laser direct deposition with its energy and environmental impact analysis. J Clean Prod, 2014, 80: 170-178.

[9]	Payne G, Ahmad A, Fitzpatrick S, et al. Remanufacturing H13 steel moulds and dies using laser metal deposition. Adv Transdiscip Eng, 2016, 3: 93-98.

[10]	Leunda J, Soriano C, Sanz C, et al. Laser cladding of vanadium-carbide tool steels for die repair. Phys Procedia, 2011, 12: 345-352.

[11]	Alegoz M, Kaya O, Bayindir ZP. A comparison of pure manufacturing and hybrid manufacturing–remanufacturing systems under carbon tax policy. Eur J Oper Res, 2021, 294(1): 161-173.

[12]	Leino M, Pekkarinen J, Soukka R. The role of laser additive manufacturing methods of metals in repair, refurbishment and remanufacturing—enabling circular economy. Phys Procedia, 2016, 83: 752-760.

[13]	Optomec Customers Surpass 10 Million Turbine Blade Repairs—Optomec (2020)

[14]	Williams SW, Martina F, Addison AC, et al. Wire + arc additive manufacturing. Mater Sci Technol, 2016, 32(7): 641-647.

[15]	IvánTabernero PA, Álvarez P, et al. Study on arc welding processes for high deposition rate additive manufacturing. Procedia CIRP, 2018, 68: 358-362.

[16]	Cunningham CR, Flynn JM, Shokrani A, et al. Invited review article: strategies and processes for high quality wire arc additive manufacturing. Addit Manuf, 2018, 22: 672-686.

[17]	Chaturvedi M, Scutelnicu E, Rusu CC, et al. Wire arc additive manufacturing: review on recent findings and challenges in industrial applications and materials characterization. Metals, 2021, 11(6): 939.

[18]	Rodrigues TA, Duarte V, Miranda RM, et al. Current status and perspectives on wire and arc additive manufacturing (WAAM). Materials, 2019, 12(7): 1121.

[19]	Liu J, Xu Y, Ge Y, et al. Wire and arc additive manufacturing of metal components: a review of recent research developments. Int J Adv Manuf Technol, 2020, 111(1/2): 149-198.

[20]	Wu B, Pan ZX, Ding DH, et al. A review of the wire arc additive manufacturing of metals: properties, defects and quality improvement. J Manuf Process, 2018, 35: 127-139.

[21]	Xia C, Pan ZX, Polden J, et al. A review on wire arc additive manufacturing: monitoring, control and a framework of automated system. J Manuf Syst, 2020, 57: 31-45.

[22]	Li Y, Han Q, Horváth I, et al. Repairing surface defects of metal parts by groove machining and wire + arc based filling. J Mater Process Technol, 2019, 274: 116268.

[23]	Chen C, Wang Y, Ou H, et al. A review on remanufacture of dies and moulds. J Clean Prod, 2014, 64: 13-23.

[24]	Zhang J, Zhou J, Wang Q, et al. Process planning of automatic wire arc additive remanufacturing for hot forging die. Int J Adv Manuf Technol, 2020, 109(5/6): 1613-1623.

[25]	Koehler H, Partes K, Seefeld T, et al. Laser reconditioning of crankshafts: from lab to application. Phys Procedia, 2010, 5: 387-397.

[26]	Vishnukumar M, Pramod R, Rajesh KA. Wire arc additive manufacturing for repairing aluminium structures in marine applications. Mater Lett, 2021, 299: 130112.

[27]	Wang Y, Chu X, Su G, et al. Laser cladding with grinding processing of orthogonal offset face gear. Int J Adv Manuf Technol, 2019, 100(5/8): 1741-1753.

[28]	Zhu L, Wang S, Pan H, et al. Research on remanufacturing strategy for 45 steel gear using H13 steel powder based on laser cladding technology. J Manuf Process, 2020, 49: 344-354.

[29]	Zhu Y, Yang Y, Mu X, et al. Study on wear and RCF performance of repaired damage railway wheels: assessing laser cladding to repair local defects on wheels. Wear, 2019, 430(431): 126-136.

[30]	Le VT, Paris H. On the use of gas-metal-arc-welding additive manufacturing for repurposing of low-carbon steel components: microstructures and mechanical properties. Weld World, 2021, 65(1): 157-166.

[31]	Zhuo Y, Yang C, Fan C, et al. Microstructure and mechanical properties of wire arc additive repairing Ti-6.5Al-2Sn-2Zr-4Mo-4Cr titanium alloy. Mater Sci Technol, 2020, 36(15): 1712-1719.

[32]	Li X, Han Q, Zhang G. Large-size sprocket repairing based on robotic GMAW additive manufacturing. Weld World, 2021, 65(5): 793-805.

[33]	Liberini M, Astarita A, Campatelli G, et al. Selection of optimal process parameters for wire arc additive manufacturing. Procedia CIRP, 2017, 62: 470-474.

[34]	Rafieazad M, Vahedi NA, Ghaffari M, et al. On microstructure and mechanical propertiesof a low-carbon low-alloy steel block fabricated by wire arc additive manufacturing. J Mater Eng Perform, 2021, 30: 4937-4945.

[35]	Wächter M, Leicher M, Hupka M, et al. Monotonic and fatigue properties of steel material manufactured by wire arc additive manufacturing. Appl Sci, 2020, 10(15): 5238.

[36]	Plangger J, Schabhüttl P, Vuherer T, et al. CMT additive manufacturing of a high strength steel alloy for application in crane construction. Metals, 2019, 9(6): 1-14.

[37]	Aiyiti W, Zhao W, Lu B, et al. Investigation of the overlapping parameters of MPAW-based rapid prototyping. Rapid Prototyp J, 2006, 12(3): 165-172.

[38]	Cao Y, Zhu S, Liang X, et al. Overlapping model of beads and curve fitting of bead section for rapid manufacturing by robotic MAG welding process. Robot Comput Integr Manuf, 2011, 27(3): 641-645.

[39]	Suryakumar S, Karunakaran KP, Bernard A, et al. Weld bead modeling and process optimization in hybrid layered manufacturing. CAD Comput Aided Des, 2011, 43(4): 331-344.

[40]	Xiong J, Zhang G, Gao H, et al. Modeling of bead section profile and overlapping beads with experimental validation for robotic GMAW-based rapid manufacturing. Robot Comput Integr Manuf, 2013, 29(2): 417-423.

[41]	Ding D, Pan Z, Cuiuri D, et al. A multi-bead overlapping model for robotic wire and arc additive manufacturing (WAAM). Robot Comput Integr Manuf, 2015, 31: 101-110.

[42]	Li Y, Sun Y, Han Q, et al. Enhanced beads overlapping model for wire and arc additive manufacturing of multi-layer multi-bead metallic parts. J Mater Process Technol, 2018, 252: 838-848.

[43]	Lee CM, Woo WS, Roh YH. Remanufacturing: trends and issues. Int J Precis Eng Manuf Green Technol, 2017, 4(1): 113-125.

[44]	Onuike B, Bandyopadhyay A. Additive manufacturing in repair: influence of processing parameters on properties of Inconel 718. Mater Lett, 2019, 252: 256-259.

[45]	Retrofix\|Additive manufacturing for repairing of metal part (2020)

[46]	Sarathchandra DT, Davidson MJ, Visvanathan G. Parameters effect on SS304 beads deposited by wire arc additive manufacturing. Mater Manuf Process, 2020, 35(7): 852-858.

[47]	European Standards, British Standard BS EN 1011-2:2001, vol 3, no 1 (2000)

[48]	Zhou X, Tian QH, Du YX, et al. Investigation of the effect of torch tilt and external magnetic field on arc during overlapping deposition of wire arc additive manufacturing. Rapid Prototyp J, 2021, 27(1): 24-36.

[49]	Jafari D, Vaneker THJ, Gibson I. Wire and arc additive manufacturing: opportunities and challenges to control the quality and accuracy of manufactured parts. Mater Des, 2021, 202: 171.