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Development and Implementation of Wire Arc Additive Manufacturing (WAAM) Based on Pulse Spray GMAW for Aluminum Alloy (AlSi7Mg)

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Abstract

Wire arc additive manufacturing (WAAM) is a manufacturing technology that uses an arc welding process to produce metal parts additively. The key attraction of WAAM for industries is the low cost per component and short production lead time, when components are required in small quantity for applications such as complex components of prototypes and parts for repairs/breakdown replacement. This paper presents the experience in the development of a cost-effective WAAM system on the basis of pulse spray gas metal arc welding; method of feasibility assessment for selection of applications; selection of welding variables; effect of different heat treatments on mechanical properties in the three spatial directions of test builds made additively; and manufacturing of near shape components by WAAM. Mechanical properties of test builds made by WAAM followed by heat treatment meet the requirements specified for the parts. This is an energy efficient way of making parts which are traditionally made through forging/casting route that can take months to manufacture.

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Authors and Affiliations

  1. Larsen & Toubro Limited, Defence Engineering, Hazira Manufacturing Complex, Gujarat, India

    Mayur Patel, Sanjiv Mulgaonkar, Hemal Desai & Tushar Borse

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  1. Mayur Patel
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  2. Sanjiv Mulgaonkar
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  3. Hemal Desai
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  4. Tushar Borse
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Correspondence to Mayur Patel.

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Patel, M., Mulgaonkar, S., Desai, H. et al. Development and Implementation of Wire Arc Additive Manufacturing (WAAM) Based on Pulse Spray GMAW for Aluminum Alloy (AlSi7Mg). Trans Indian Inst Met 74, 1129–1140 (2021). https://doi.org/10.1007/s12666-020-02154-w

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