Wire-feed additive manufacturing of metal components: technologies, developments and future interests

Wire-feed additive manufacturing of metal components: technologies, developments and future interests

2015 | Donghong Ding, Zengxi Pan, Dominic Cuiuri, Huijun Li
Wire-feed additive manufacturing (AM) is a promising alternative to traditional subtractive manufacturing for producing large, expensive metal components with complex geometries. Current research focuses on creating complex-shaped functional metal components with high geometry accuracy, surface finish, and material properties to meet demands in aerospace, automotive, and rapid tooling industries. However, wire-feed AM processes often result in high residual stresses and distortions due to excessive heat input and high deposition rates. Understanding the effects of process parameters such as energy input, wire-feed rate, welding speed, deposition pattern, and sequence on thermal history and residual stresses is crucial. Poor accuracy and surface finish limit the application of wire-feed AM. This paper reviews various wire-feed AM technologies, their characteristics, and process aspects, including quality and accuracy of processed components. The goal is to identify current challenges and future research directions. Additive manufacturing (AM) has gained attention in the manufacturing industry, especially for creating part models and prototypes. Originally used for polymer parts, AM is now used in final production. To meet demands in aerospace, automotive, and rapid tooling industries, AM research has shifted to fabricate complex-shaped metal components, including titanium and nickel alloys, which are difficult to produce using conventional methods. AM has several advantages over conventional subtractive manufacturing, such as CNC machining. It allows complete automation from design to fabrication, reducing production time and human intervention. AM is also cost-competitive for expensive materials like titanium and nickel. AM can create complex structures that are impractical with traditional methods. AM technologies for metal components are classified into powder bead fusion, directed energy deposition, binder jetting, and sheet lamination. Metal powder and wire are typical additive materials. Powder-feed/-bed processes are more developed, offering high geometrical accuracy, but have low deposition rates. Wire-feed AM has higher deposition rates and material efficiency, but lower resolution and complexity. There is a trade-off between deposition rate and resolution when selecting an AM process. Wire-feed AM can produce large components economically, but has lower resolution and complexity compared to powder-feed/-bed processes.Wire-feed additive manufacturing (AM) is a promising alternative to traditional subtractive manufacturing for producing large, expensive metal components with complex geometries. Current research focuses on creating complex-shaped functional metal components with high geometry accuracy, surface finish, and material properties to meet demands in aerospace, automotive, and rapid tooling industries. However, wire-feed AM processes often result in high residual stresses and distortions due to excessive heat input and high deposition rates. Understanding the effects of process parameters such as energy input, wire-feed rate, welding speed, deposition pattern, and sequence on thermal history and residual stresses is crucial. Poor accuracy and surface finish limit the application of wire-feed AM. This paper reviews various wire-feed AM technologies, their characteristics, and process aspects, including quality and accuracy of processed components. The goal is to identify current challenges and future research directions. Additive manufacturing (AM) has gained attention in the manufacturing industry, especially for creating part models and prototypes. Originally used for polymer parts, AM is now used in final production. To meet demands in aerospace, automotive, and rapid tooling industries, AM research has shifted to fabricate complex-shaped metal components, including titanium and nickel alloys, which are difficult to produce using conventional methods. AM has several advantages over conventional subtractive manufacturing, such as CNC machining. It allows complete automation from design to fabrication, reducing production time and human intervention. AM is also cost-competitive for expensive materials like titanium and nickel. AM can create complex structures that are impractical with traditional methods. AM technologies for metal components are classified into powder bead fusion, directed energy deposition, binder jetting, and sheet lamination. Metal powder and wire are typical additive materials. Powder-feed/-bed processes are more developed, offering high geometrical accuracy, but have low deposition rates. Wire-feed AM has higher deposition rates and material efficiency, but lower resolution and complexity. There is a trade-off between deposition rate and resolution when selecting an AM process. Wire-feed AM can produce large components economically, but has lower resolution and complexity compared to powder-feed/-bed processes.
Reach us at info@futurestudyspace.com