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Applications of wire arc additive manufacturing (WAAM) for aerospace component manufacturing

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Abstract

Wire arc additive manufacturing (WAAM) is an emerging technology for metal processing that offers many advantages for aerospace-grade production. It provides significant design complexity and freedom offering very fast material deposition rates and relatively good material properties. It is also based on simple hardware and materials and is easy to apply in the field, making it an ideal tool for the aerospace industry. This article reviewed the major application sectors in the aerospace industry where WAAM has been successfully used with some examples, some of the aerospace-relevant modeling and simulation work for WAAM that has been done, and the current status of the significantly used WAAM materials of interest to the aerospace industry (particularly, aluminum, titanium, and nickel alloys). It was found that the most important benefits offered by WAAM to the aerospace industry were its very fast material deposition rate, its flexibility and simplicity, and its ability to process aluminum alloys much more effectively than most other AM processes. There are still areas to be explored before WAAM could be fully integrated into the aerospace design and manufacturing system, but it is well on its way and promises to be an essential technology in the future.

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Authors and Affiliations

  1. Department of Manufacturing Engineering, School of Mechanical Engineering, Vellore Institute of Technology, Vellore, 632014, Tamil Nadu, India

    Harshita Pant & Anisha Arora

  2. Department of Space Engineering, University of Surrey, Surrey, Guildford, GU2 9GU, UK

    Ganga Sutha Gopakumar

  3. Department of Materials Science and Engineering, University of Toronto, Toronto, Ontario, M5S 2Z9, Canada

    Utkarsh Chadha

  4. Department of Engineering Technology and Industrial Distribution, Texas A &M University, College Station, TX, 77843, USA

    Amir Saeidi & Albert E. Patterson

  5. Department of Materials Science and Engineering, University of California, Davis, Davis, CA, 96516, USA

    Amir Saeidi

  6. J. Mike Walker ’66 Department of Mechanical Engineering, Texas A &M University, College Station, TX, 77843, USA

    Albert E. Patterson

Authors
  1. Harshita Pant
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  2. Anisha Arora
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  3. Ganga Sutha Gopakumar
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  4. Utkarsh Chadha
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  5. Amir Saeidi
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  6. Albert E. Patterson
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Contributions

HP: Study design, literature collection and analysis, first draft section writing. AA: Study design, literature collection and analysis, first draft section writing. GSG: Study design, literature collection and analysis, first draft section writing. UC: Study design, review coordination, literature collation, first draft preparation, figures. AS: Study design, supervision, literature collection and analysis, figures, final draft preparation and polishing. AEP: Supervision, study design, literature collection, figures, final draft preparation and polishing, journal submission and correspondence. All opinions and conclusions are solely those of the authors.

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Correspondence to Albert E. Patterson.

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Pant, H., Arora, A., Gopakumar, G.S. et al. Applications of wire arc additive manufacturing (WAAM) for aerospace component manufacturing. Int J Adv Manuf Technol 127, 4995–5011 (2023). https://doi.org/10.1007/s00170-023-11623-7

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  • DOI: https://doi.org/10.1007/s00170-023-11623-7

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