Introduction to the design rules for Metal Big Area Additive Manufacturing

Greer, Clayton; Nycz, Andrzej; Noakes, Mark; Richardson, Brad; Post, Brian; Kurfess, Thomas; Love, Lonnie

doi:10.1016/j.addma.2019.02.016

Introduction to the design rules for Metal Big Area Additive Manufacturing

Journal Article · Sun Feb 24 23:00:00 EST 2019 · Additive Manufacturing

DOI:https://doi.org/10.1016/j.addma.2019.02.016· OSTI ID:1504003

Greer, Clayton ^[1]; ^[1]; ^[1]; ^[1]; ^[1]; Kurfess, Thomas ^[1]; ^[1]

Georgia Inst. of Technology, Atlanta, GA (United States)

Wire feed metal additive manufacturing offers advantages, such as large build volumes and high build rates, over powder bed and blown powder techniques, but it has its own disadvantages, i.e., lower feature resolution and bead morphology control issues. A new wire feed metal additive manufacturing process called Metal Big Area Additive Manufacturing (mBAAM) uses a Gas Metal Arc Weld system on an articulated robot arm to increase build volume and deposition rate in comparison to powder bed techniques. The high deposition rate implies a low-resolution process; therefore, parts designed for mBAAM must incorporate the use of machining to achieve certain features. Here, this paper presents an introduction to how design rules, such as overhang constraint, large weld bead thickness, and support structure, for mBAAM interact in the context of an excavator arm case study, which was designed using topology optimization.

Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE)

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 1504003

Journal Information:: Additive Manufacturing, Journal Name: Additive Manufacturing Journal Issue: C Vol. 27; ISSN 2214-8604

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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Current Status and Perspectives on Wire and Arc Additive Manufacturing (WAAM) Rodrigues, Tiago A.; Duarte, V.; Miranda, R. M. Materials, Vol. 12, Issue 7 https://doi.org/10.3390/ma12071121	journal	April 2019
Adaptive process control implementation of wire arc additive manufacturing for thin-walled components with overhang features Lam, Teng Foong; Xiong, Yi; Dharmawan, Audelia Gumarus The International Journal of Advanced Manufacturing Technology, Vol. 108, Issue 4 https://doi.org/10.1007/s00170-019-04737-4	journal	December 2019
State of the Art in Directed Energy Deposition: From Additive Manufacturing to Materials Design Dass, Adrita; Moridi, Atieh Coatings, Vol. 9, Issue 7 https://doi.org/10.3390/coatings9070418	journal	June 2019

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42 ENGINEERING
Arc Weld Deposition
Design for Additive Manufacturing
Metal Big Area Additive Manufacturing
Topology Optimization

Introduction to the design rules for Metal Big Area Additive Manufacturing

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