New publication on Plasma Wire Arc Manufacturing Process - Modelling by
Marcel Czipin, Alexander Wenda, Karin Hartl, Emre Akalin, Martin Stockinger
Thermo mechanical Finite Element Analysis of the plasma Wire Arc Additive Manufacturing process in DEFORM® 13,
Journal of Advanced Joining Processes, Volume 12, 2025, 100321, ISSN 2666-3309,
doi.org/10.1016/j.jajp.2025.100321.
(https://www.sciencedirect.com/science/article/pii/S2666330925000421)
Abstract: This study investigates the potential of Finite Element Analysis in DEFORM® to predict the thermal history, deformation, residual stress state and grain growth in the Wire Arc Additive Manufacturing processes of Ti–6Al–4V. The temperature dependent material model for Ti–6Al–4V was extended and adapted to improve the representation of contact boundary conditions within DEFORM®, focusing on Additive Manufacturing. A single layer quad-mesh approach was employed alongside dummy heat sources to simulate the process by accurate layer wise activation within the arc welding module. The model utilized a normalized double-ellipsoid heat source and introduced a power adaptation strategy to account for differences in volumetric deposition. The extracted thermal history showed very good agreement to corresponding thermocouple measurements. The accuracy of the resulting deformation state was validated using a 3D scan, while the predicted grain size distribution was compared against an as-built micrograph. The simulation showed good overall accuracy, though limitations were noted in the grain size model, which was inadequate in predicting the more complex texture of the mixed α/β-microstructure typical for Ti–6Al–4V. Seven heat treatment strategies were evaluated to address mechanical anisotropy. Solution annealing followed by water quenching and subsequent low temperature aging was found to be most effective.
Keywords: Wire Arc Additive Manufacturing; Finite Element Analysis; DEFORM®; Ti–6Al–4V; Grain growth
NEW WAAM Lab
At the Chair of Metall Forming, a cutting-edge lab for Wire Arc Additive Manufacturing (WAAM) has been established. The Cyber-Physical Robot Cell for WAAM conducts process studies and develops optimal parameter sets. A physically assisted AI approach supports experimental work to build in-depth process knowledge. Further Reading
Rückblick
Seminar „AM@MUL: Know-how für die industrielle Anwendung in der additiven Fertigung“
Beim Seminar „AM@MUL: Know-how für die industrielle Anwendung in der additiven Fertigung“ kamen rund 30 Experten und Expertinnen aus Forschung und Industrie zusammen, um sich über den aktuellen Stand der additiven Fertigung auszutauschen.
Die Vorträge deckten ein breites Spektrum ab: von innovativen Ansätzen in der Prozesstechnik über spezielle neue Materialien für die additive Fertigung bis hin zur Charakterisierung und Prüftechnik von gedruckten Teilen. Auch Themen wie nationale Fördermöglichkeiten für AM-orientierte Projekte sowie Umweltaspekte und Energiebedarf von AM-Verfahren wurden ausführlich behandelt.
Darüber hinaus bot die Veranstaltung zahlreiche Gelegenheiten zur Vernetzung und zum Anstoßen neuer Kooperationen.
Die Veranstaltung wurde von der AM@MUL im Kooperation mit Industriepartner Lithou, Hage3D, AMA Austria, Metalpine, Luxinergy und Resch-Fertigungstechnik und Prototypenbau durchgeführt.
Post Event Report
Around 30 experts from research and industry came together at the "AM@MUL: Know-how for industrial applications in additive manufacturing" seminar to discuss the current state of additive manufacturing.
The presentations covered a broad spectrum: from innovative approaches in process technology and special new materials for additive manufacturing to the characterization and testing technology of printed parts. Topics such as national funding opportunities for AM-oriented projects as well as environmental aspects and the energy requirements of AM processes were also covered in detail.
In addition, the event offered numerous opportunities for networking and initiating new collaborations.
The event was organized by AM@MUL in cooperation with industry partners Lithou, Hage3D, AMA Austria, Metalpine, Luxinergy and Resch-Fertigungstechnik und Prototypenbau.
Leoben, 20.6.2024