WAAM of structural components—building strategies for varying wall thicknesses

Abstract Additive manufacturing with steel opens up new possibilities for individual parts or complex supply chains. The direct energy deposition process DED-arc, also known as wire arc additive (WAAM), is particularly suited large structures a high degree of geometrical freedom. design freedom makes WAAM ideal creating force-flow-optimized nodes and spaceframes use in the construction industry. Thick-walled can be manufactured manifold strategies variety infill patterns, like hachure, spiral, meander well without contour path. For varying thicknesses, not all them apply. If wall thickness changes increments smaller than width weld bead, desired shape cannot made by selecting one available but distance (overlap) between beads needs to varied. A variation bead overlap often lead compromised build quality due presence voids. Thus, utilizing variable requires development parameter set that allows deviation from defined values running risk introducing voids layers. In this study, four sets were analyzed regarding their geometry, tolerance ranges identified each set. They found vary 15 50% overlap, depending on its corresponding geometry. geometry surface last deposited layer was evaluated height difference. It stated that, decreasing feed, welded becomes smoother. findings obtained are transferred parts. As result, building direction distances.