Wire arc additive manufacturing method

Sviridov A.V., Fomicheva O.V., Golev E.V., Kozyreva O.E.
UDC
621.791
DOI
10.18577/2307-6046-2025-0-6-31-45
Article PDF (Russian) (825.32 KB)
How to cite
Sviridov A.V., Fomicheva O.V., Golev E.V., Kozyreva O.E. Wire arc additive manufacturing method // Proceedings of VIAM. 2025. No. 6. DOI: 10.18577/2307-6046-2025-0-6-31-45. URL: https://test.viam.ru/en/journal/2025/6/3
Keywords
additive manufacturing, wire arc additive manufacturing (WAAM), gas meral arc welding (GMAW), plasma arc welding (PAW), cold metal transfer (CMT), laser metal deposition (LMD), electron beam additive manufacturing (EBAM)
Abstract

The article presents the main stages of development of wire arc cladding (WAAM) technology. The experience of using WAAM for various groups of materials (steel, nickel, titanium, aluminum and other alloys) is presented. The main problematic issues and methods for improving quality of workpieces obtained by WAAM technology are considered. Advantages of the technology are low labor intensity, high material utilization factor and productivity; the ability to synthesize and restore large-sized parts; less science-intensive production of wire compared to metal powders.

Reference list
  1. Kablov E.N., Evgenov A.G., Bakradze M.M., Nerush S.V., Krupnina O.A. New generation materials and digital additive technologies for the production of resource parts of FSUE «VIAM». Part 1. Materials and synthesis technologies. Elektrometallurgiya, 2022, no. 1, pp. 2–12.
  2. Kablov E.N., Evgenov A.G., Bakradze M.M., Nerush S.V., Krupnina O.A. New generation materials and digital additive technologies for the production of resource parts of FSUE «VIAM». Part 2. Compensation and control of deviations, GIP and heat treatment. Elektrometallurgiya, 2022, no. 2, pp. 2–12.
  3. Kablov E.N., Evgenov A.G., Petrushin N.V., Bazyleva O.A., Mazalov I.S., Dynin N.V. New generation materials and digital additive technologies for the production of resource parts of FSUE «VIAM». Part 3. Adaptation and creation of materials. Elektrometallurgiya, 2022, no. 4, pp. 5–25.
  4. Kablov E.N., Evgenov A.G., Petrushin N.V., Bazyleva O.A., Mazalov I.S. New generation materials and digital additive technologies for the production of resource parts of FSUE «VIAM». Part 4. Development of heat-resistant materials. Elektrometallurgiya, 2022, no. 5, pp. 8–19.
  5. Khodykin L.G., Nyafkin A.N., Kosolapov D.V., Zhabin A.N. Laser welding of metal composite materials based on aluminium alloy reinforced with refractory particles SiC (review). Trudy VIAM, 2022, no. 12 (118), paper no. 06. Available at: http://www.viam-works.ru (accessed: July 23, 2024). DOI: 10.18577/2307-6046-2022-0-12-63-75.
  6. Kablov E.N., Antipov V.V., Sviridov A.V., Gribkov М.S. Features of electron beam welding of heat-resistant alloys EI698-VD and EP718-ID with steel 45. Trudy VIAM, 2020, no. 9 (91), paper no. 01. Available at: http://www.viam-works.ru (accessed: August 02, 2024). DOI: 10.18577/2307-6046-2020-0-9-3-14.
  7. Panteleev M.D., Sviridov A.V., Skupov A.A., Odintsov N.S. Perspective welding technologies of aluminum-lithium alloy V-1469 applied to fuselage panels. Trudy VIAM, 2020, no. 12 (94), paper no. 04. Available at: http://www.viam-works.ru (accessed: August 02, 2024). DOI: 10.18577/2307-6046-2020-0-12-35-46.
  8. Panteleev M.D., Sviridov A.V., Nerush S.V., Bondarenko S.V., Mostyaev I.V. Weldability features of heat-resistant aluminum alloys. Trudy VIAM, 2023, no. 12 (130), paper no. 03. Available at: http://www.viam-works.ru (accessed: August 02, 2024). DOI: 10.18577/2307-6046-2023-0-12-28-37.
  9. Benarieb I., Antipov V.V., Khasikov D.V., Oglodkov M.S., Savichev I.D., Kuznetsova P.E. Study of structure and properties of sparinly alloyed aluminum alloy of Al–Mg–Sc–Zr system, produced by selective laser melting. Aviation materials and technologies, 2023, no. 4 (73), paper no. 03. Available at: http://www.journal.viam.ru (accessed: August 02, 2024). DOI: 10.18577/2713-0193-2023-0-4-23-35.
  10. Kolyadov E.V., Visik E.M., Gerasimov V.V., Bityutskaya O.N. Features of the morphology of the structure of nickel superalloy depending on the values of the axial and radial temperature gradients at the crystallization front. Aviation materials and technologies, 2024, no. 2 (75), paper no. 02. Available at: http://www.journal.viam.ru (accessed: August 02, 2024). DOI: 10.18577/2713-0193-2024-0-2-15-24.
  11. Oglodkov M.S., Shchetinina N.D., Rudchenko A.S., Panteleev M.D. Directions of the develop-ment of promising aluminum-lithium alloys for aero-space engineering (review). Aviacionnye materialy i tehnologii, 2020, no. 1 (58), pp. 19–29. DOI: 10.18577/2071-9140-2020-0-1-19-29.
  12. Skupov A.A., Sviridov A.V., Golev E.V., Stekolnikova E.Yu. Laser welding of heat-resistant alloy nickel base for gas turbine elements engines. Aviation materials and technologies, 2023, no. 4 (73), paper no. 01. Available at: http://www.journal.viam.ru (accessed: August 02, 2024). DOI: 10.18577/2713-0193-2023-0-4-3-13.
  13. Ding J., Colegrove P., Mechnen J. et al. Thermo-mechanical analysis of wire and arc additive layer Manufacturing process on large multi-layer parts. Computational Materials Science, 2011, vol. 50, no.12, pp. 3315–3322.
  14. Pattanayak S., Sahoo S.K. Gas metal arc welding based additive manufacturing ‒ a review. CIRP Journal of Manufacturing Science and Technology, 2021, no. 33, pp. 398–442. DOI: 10.1016/j.cirpj.2021.04.010.
  15. Wu B., Pan Z., Ding D. et al. A review of the wire arc additive manufacturing of metals: Properties, defects and quality improvement. Journal of Manufacturing Processes, 2018, no. 35, pp. 127–139.
  16. Spencer J., Dickens P., Wykes C. Rapid prototyping of metal parts by three-dimensional welding. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 1998, vol. 212, no. 3, pp. 175–182.
  17. Wang Y., Chen X., Konovalov S.V. Additive manufacturing based on welding arc: a low-cost method. Journal of Surface Investigation: X-Ray, Synchrotron Neutron Technologies, 2017, no. 11, pp. 1317–1328. DOI: 10.1134/S1027451017060210.
  18. Ding D., Pan Z., Cuiuri D., Li H. Wire-feed additive manufacturing of metal components: technologies, developments and future interests. The International Journal of Advanced Manufacturing Technologies, 2015, no. 81, pp. 465–481. DOI: 10.1007/s00170-015-7077-3.
  19. Artaza T., Suarez A., Veiga F. et al. Wire arc additive manufacturing Ti6Al4V aeronautical parts using plasma arc welding: Analysis of heat-treatment processes in different atmospheres. Journal of Materials Research Technologies, 2020, no. 9, pp. 15454–15466. DOI: 10.1016/j.jmrt.2020.11.012.
  20. Singh P., Dutta D. Multi-direction slicing for layered manufacturing. Journal of Computing and Informational Science in Engineering, 2001, no. 1, pp. 129–142. DOI: 10.1115/1.1375816.
  21. Jafari D., Vaneker T.H.J., Gibson I. Wire and arc additive manufacturing: opportunities and challenges to control the quality and accuracy of manufactured parts. Material Design, 2021, vol. 202, no. 109471. DOI: 10.1016/j. matdes.2021.109471.
  22. Ding D., Pan Z., Cuiuri D., Li H. A practical path planning methodology for wire and arc additive manufacturing of thin-walled structures. Robotics and Computer-Integrated Manufacturing, 2015, no. 34, pp. 8–19. DOI: 10.1016/j.rcim.2015.01.003.
  23. Artaza T., Suarez A., Murua M. Wire arc additive manufacturing of Mn4Ni2CrMo steel: comparison of mechanical and metallographic properties of PAW and GMAW. Procedia Manufacturing, 2019, no. 41, pp. 1071–1078. DOI: 10.1016/j.promfg.2019.10.035.
  24. Ahiale G.K., Oh Y.-J., Choi W.-D. et al. Microstructure and fatigue resistance of high strength dual phase steel welded with gas metal arc welding and plasma arc welding processes. Metals and Materials International, 2013, no. 19, pp. 933–939. DOI: 10.1007/s12540-013-5005-3.
  25. Wu Q., Lu J., Liu C. et al. Obtaining uniform deposition with variable wire feeding direction during wire-feed additive manufacturing. Materials Manufacturing Processes, 2017, no. 32, pp. 1881–1886. DOI: 10.1080/10426914.2017.1364860.
  26. Wu B., Ding D., Pan Z. et al. Effects of heat accumulation on the arc characteristics and metal transfer behavior in Wire Arc Additive Manufacturing of Ti6Al4V. Journal of Material Processing Technology, 2017, no. 250, pp. 304–312. DOI: 10.1016/j.jmatprotec.2017.07.037.