Out of all the metal additive manufacturing (AM) techniques, the directed energy deposition (DED) technique, and particularly the wire-based one, are of great interest due to their rapid production. The optimization parametric study and modification of WAAM to reduce both residual stress and distortion are tabulated, summarized, and discussed. In this paper, wire-based and wire arc technology processes for 3D metal printing, including their advantages and limitations are reviewed. Distortion and residual stress are always a challenge for WAAM because they can affect the component’s geometric accuracy and drastically degrade the mechanical properties of the components. WAAM is gaining popularity in the fabrication of 3D metal components, but the process is hard to control due to its inherent residual stress and distortion, which are generated by the high thermal input from its heat sources. Unlike MIG, tungsten inert gas welding (TIG) and plasma arc welding (PAW) need an external wire feed machine to supply the additive materials. MIG is easier and more convenient than TIG and PAW because it uses a continuous wire spool with the welding torch. There are three heat sources commonly used in WAAM: metal inert gas welding (MIG), tungsten inert gas welding (TIG), and plasma arc welding (PAW). Generally, AM technology is used to overcome the limitations of traditional subtractive manufacturing (SM) for fabricating large-scale components with lower buy-to-fly ratios. It is increasingly being used worldwide to reduce costs and time. Discuss in the Arc 3D Printer forum thread on arc additive manufacturing (WAAM) is a crucial technique in the fabrication of 3D metallic structures. Let’s hear your thoughts on whether or not such a printer would work, and if it would really be an entire order of magnitude faster than whats on the market today. The project does seem to be backburnered for now, but we’ll keep looking out for more updates! Below you will find a quick video describing an arc welding process, so that you can get a better feel for what is involved in this concept. Whether this type of arc printer will work like the designer believes it should is yet to be seen. The Hackaday user believes that such a machine would be capable of printing at ten times the speed of the fastest metal printers on the market today. Once a layer is done, the machine will vibrate slightly moving the next layer of metal powder onto the build platform, the arm will lift, and the process repeats. Working from the center out, an entire layer can be welded in a matter of seconds. At this point the arm is in contact with the metal powder, and an electrical current is sent to the arm. An arm will come down on top of the metal powder on the build platform. The Arc printer would work by using a thin layer of metal powder, which is printed layer by layer. The printer could easily be scaled up by simply adding additional wire arrays. The arrays would be individual modules which correlate to the X and Y coordinates fed to the printer via a slicing software. The head of the printer would be at the bottom of the print platform, which consists of many small wires placed in a 256 x 256 array. Sort of like many SLA printers which use UV light to cure a resin, this machine also works from the bottom up. The electric arc is able to produce intense heat of close to 6,500 degrees F, instantly melting and fusing the electrode and base metals. It is based on the same process used in the arc welding field, and according to the project’s designer, “the Arc printer is a rapid printing 3D printer with minimal moving parts designed to print objects in minutes not hours.”įor those of you unfamiliar with how arc welding works, it is a fusion welding process which uses a welding power supply to create an electric arc between an electrode and a base material which is fuses the metals together. The method described by ‘0n37w0’ is called arc printing. The self-proclaimed ‘Fixer of Things’ has posted a project on the site, which is dedicated to serving up fresh ‘hacks’ every day from around the internet.Īlthough the Hackaday user is limited on funding and time, he is slowly working on this idea, which he has posted in full at Hackaday.io. One member of Hackaday.io, who goes by the handle of ‘on37w0’ (and introduces himself as George in his project’s video), thinks he may have discovered a new technique to 3D print metal objects at speeds which currently seem like a pipe dream.
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