Skip to main content
SpringerLink
Log in

Design, Integrating and Controlling of Mig-Based Shaped Metal Deposition System with Externally Cold Wire Feed in Additive Layered Manufacturing Technology

  • Research Article-Mechanical Engineering
  • Published:
Arabian Journal for Science and Engineering Aims and scope Submit manuscript

Abstract

Cold wire feeding plus MIG-based shaped metal deposition process has been proved to be a promising technology capable of using materials and energies reasonably to manufacture complex large-scale metal components. The shaped metal deposition with cold wire feeding process is suitable as an alternative technique for traditional manufacturing methods, especially for complex and large-scale solid parts and it is especially used for structural components in aerospace and the manufacture and repair of dying/molds. In this paper, a new experimental setup was developed, which consists of a MIG welding source, an external cold wire feed unit and a 3-axis machine. The paper explains the design, implementation, and stages of control programing (CAD-CAM) of the developed system. Furthermore, the paper presents the important design steps from the design database using CAD to the final shape of the part to be configured. The proposed system is capable of producing parts of different shapes in sizes of more than 450 mm directly from the computer-aided design. Several components are fabricated with SS309L components to achieve the capability of the advanced proposed system. The results showed that the integrated system and the program are feasible and flexible and hence can be used to manufacture variously shaped parts.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15

Similar content being viewed by others

References

  1. Huang, R.; Riddle, M.; Graziano, D.; Warren, J.; Das, S.; Nimbalkar, S.; et al.: Energy and emissions saving potential of additive manufacturing: the case of lightweight aircraft components. J. Clean. Prod. 135, 1559–1570 (2016)

    Article  Google Scholar 

  2. Frazier, W.E.: Metal additive manufacturing: a review. J. Mater. Eng. Perform. 23(6), 1917–1928 (2014)

    Article  Google Scholar 

  3. Baufeld, B.; Van der Biest, O.; Gault, R.: Additive manufacturing of Ti–6Al–4V components by shaped metal deposition: microstructure and mechanical properties. Mater. Des. 31, S106–S111 (2010)

    Article  Google Scholar 

  4. Ding, D.; Pan, Z.; Cuiuri, D.; Li, H.; Larkin, N.: Adaptive path planning for wire-feed additive manufacturing using medial axis transformation. J. Clean. Prod. 133, 942–952 (2016)

    Article  Google Scholar 

  5. Ugla, A.A.; Yilmaz, O.; Almusawi, A.R.: Development and control of shaped metal deposition process using tungsten inert gas arc heat source in additive layered manufacturing. Proc. Inst. Mech. Eng. Part B J. Eng. Manuf. 232(9), 1628–1641 (2018)

    Article  Google Scholar 

  6. Bonaccorso, F.; Cantelli, L.; Muscato, G.: Arc welding control for shaped metal deposition process. IFAC Proc. Vol. 44(1), 11636–11641 (2011)

    Article  Google Scholar 

  7. Yilmaz, O.; Ugla, A.A.: Microstructure characterization of SS308LSi components manufactured by GTAW-based additive manufacturing: shaped metal deposition using pulsed current arc. Int. J. Adv. Manuf. Technol. 89(1–4), 13–25 (2017)

    Article  Google Scholar 

  8. Wang, J.F.; Sun, Q.J.; Wang, H.; Liu, J.P.; Feng, J.C.: Effect of location on microstructure and mechanical properties of additive layer manufactured Inconel 625 using gas tungsten arc welding. Mater. Sci. Eng., A 676, 395–405 (2016)

    Article  Google Scholar 

  9. Xiong, J.; Zhang, G.; Hu, J.; Wu, L.: Bead geometry prediction for robotic GMAW-based rapid manufacturing through a neural network and a second-order regression analysis. J. Intell. Manuf. 25(1), 157–163 (2014)

    Article  Google Scholar 

  10. Spencer, J.D.; Dickens, P.M.; Wykes, C.M.: Rapid prototyping of metal parts by three-dimensional welding. Proc. Inst. Mech. Eng. Part B J. Eng. Manuf. 212(3), 175–182 (1998)

    Article  Google Scholar 

  11. Xiong, J.; Lei, Y.; Chen, H.; Zhang, G.: Fabrication of inclined thin-walled parts in multi-layer single-pass GMAW-based additive manufacturing with flat position deposition. J. Mater. Process. Technol. 240, 397–403 (2017)

    Article  Google Scholar 

  12. Lin, J.J.; Lv, Y.H.; Liu, Y.X.; Xu, B.S.; Sun, Z.; Li, Z.G.; Wu, Y.X.: Microstructural evolution and mechanical properties of Ti–6Al–4V wall deposited by pulsed plasma arc additive manufacturing. Mater. Des. 102, 30–40 (2016)

    Article  Google Scholar 

  13. Lin, J.; Lv, Y.; Liu, Y.; Sun, Z.; Wang, K.; Li, Z.; et al.: Microstructural evolution and mechanical property of Ti–6Al–4V wall deposited by continuous plasma arc additive manufacturing without post heat treatment. J. Mech. Behav. Biomed. Mater. 69, 19–29 (2017)

    Article  Google Scholar 

  14. Strano, G.; Hao, L.; Evans, K.E.; Everson, R.M.: Optimization of quality and energy consumption for additive layer manufacturing processes (2010).‏

  15. Voice, W: Net-shape processing applied to aero-engine components. Rolls-Royce Plc Derby (United Kingdom).‏ http://www.rto.nato.int/abstracts.asp (2006)

  16. Baufeld, B.; Biest, O.V.D.; Gault, R.: The microstructure of Ti–6Al–4V specimens produced by shaped metal deposition. Int. J. Mater. Res. 100(11), 1536–1542 (2009)

    Article  Google Scholar 

  17. Baufeld, B.; Van der Biest, O.: Mechanical properties of Ti–6Al–4V specimens produced by shaped metal deposition. Sci. Technol. Adv. Mater. 10(1), 015008 (2009)

    Article  Google Scholar 

  18. Clark, D.; Bache, M.R.; Whittaker, M.T.: Shaped metal deposition of a nickel alloy for aero engine applications. J. Mater. Process. Technol. 203(1–3), 439–448 (2008)

    Article  Google Scholar 

  19. Baufeld, B.; van der Biest, O.; Gault, R.; Ridgway, K: Manufacturing Ti–6Al–4V components by shaped metal deposition: microstructure and mechanical properties. In: IOP Conference Series: Materials Science and Engineering, vol. 26, no. 1, p. 012001. IOP Publishing (2011)

  20. Escobar-Palafox, G.; Gault, R.; Ridgway, K.: Robotic manufacturing by shaped metal deposition: state of the art. Ind. Robot Int. J. 38(6), 622–628 (2011)

    Article  Google Scholar 

  21. Escobar-Palafox, G.; Gault, R.; Ridgway, K: Preliminary empirical models for predicting shrinkage, part geometry and metallurgical aspects of Ti–6Al–4V shaped metal deposition builds. In: IOP Conference Series: Materials Science and Engineering, vol. 26, no. 1, p. 012002. IOP Publishing (2011)‏

  22. Heralić, A.; Christiansson, A.K.; Hurtig, K.; Ottosson, M.; Lennartson, B.: Control design for automation of robotized laser metal-wire deposition. IFAC Proc. Vol. 41(2), 14785–14791 (2008)

    Article  Google Scholar 

  23. Almeida, P.S.; Williams, S.: Innovative process model of Ti–6Al–4V additive layer manufacturing using cold metal transfer (CMT). In: Proceedings of the Twenty-First Annual International Solid Freeform Fabrication Symposium, the University of Texas at Austin, Austin, TX, USA (2010)

  24. Brandl, E.; Michailov, V.; Viehweger, B.; Leyens, C.: Deposition of Ti–6Al–4V using laser and wire, part I: microstructural properties of single beads. Surf. Coat. Technol. 206(6), 1120–1129 (2011)

    Article  Google Scholar 

  25. Antonysamy, A.A.: Microstructure, texture and mechanical property evolution during additive manufacturing of Ti6Al4V alloy for aerospace applications. Doctoral dissertation, The University of Manchester (United Kingdom) (2012)‏‏

  26. Muscato, G.; Spampinato, G.; Cantelli, L.: A closed-loop welding controller for a rapid manufacturing process. In: IEEE International Conference on Emerging Technologies and Factory Automation, 2008. ETFA 2008, pp. 1080–1083. IEEE (2008)‏

  27. Ding, J.: Thermo-mechanical analysis of wire and arc additive manufacturing process (2012)‏

  28. Yilmaz, O.; Ugla, A.A.: Shaped metal deposition technique in additive manufacturing: a review. Proc. Inst. Mech. Eng. Part B J. Eng. Manuf. 230(10), 1781–1798 (2016)

    Article  Google Scholar 

  29. Spencer, J.D.; Dickens, P.M.: Production of metal parts featuring heavy sections using 3D welding. In: Proceedings of First National Conference on Rapid Prototyping and Tooling Research, pp. 127–137. London: Mechanical Engineering Publications (1995)

  30. Mughal, M.P.; Fawad, H.; Mufti, R.A.: Three-dimensional finite-element modelling of deformation in weld-based rapid prototyping. Proc. Inst. Mech. Eng. Part C J. Mech. Eng. Sci. 220(6), 875–885 (2006)

    Article  Google Scholar 

  31. Zhang, Y.; Chen, Y.; Li, P.; Male, A.T.: Weld deposition-based rapid prototyping: a preliminary study. J. Mater. Process. Technol. 135(2–3), 347–357 (2003)

    Article  Google Scholar 

  32. Lin, H.L.: The use of the Taguchi method with grey relational analysis and a neural network to optimize a novel GMA welding process. J. Intell. Manuf. 23(5), 1671–1680 (2012)

    Article  Google Scholar 

  33. Ueyama, T.; Ohnawa, T.; Tanaka, M.; Nakata, K.: Effects of torch configuration and welding current on weld bead formation in high speed tandem pulsed gas metal arc welding of steel sheets. Sci. Technol. Weld. Joining 10(6), 750–759 (2005)

    Article  Google Scholar 

  34. Yang, D.; He, C.; Zhang, G.: Forming characteristics of thin-wall steel parts by double electrode GMAW based additive manufacturing. J. Mater. Process. Technol. 227, 153–160 (2016)

    Article  Google Scholar 

  35. Xiong, J.; Li, Y.; Li, R.; Yin, Z.: Influences of process parameters on surface roughness of multi-layer single-pass thin-walled parts in GMAW-based additive manufacturing. J. Mater. Process. Technol. 252, 128–136 (2018)

    Article  Google Scholar 

  36. AWS Code Section II Part C, 1989, Welding Rods, Electrodes, and Filler Metals

  37. Pan, Z.; Polden, J.; Larkin, N.; Van Duin, S.; Norrish, J.: Recent progress on programming methods for industrial robots. Robot. Comput. Integr. Manuf. 28(2), 87–94 (2012)

    Article  Google Scholar 

Download references

Acknowledgments

This work was done at Thi-Qar University/Faculty of Engineering, Al-Nasiriyah, Iraq.

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, College of Engineering, Advanced Manufacturing Technology Research Group, University of Thi-Qar, Al-Nasiriyah, 64001, Iraq

    Hassan J. Khaudair & Adnan A. Ugla

  2. Department of Mechatronics Engineering, College of Engineering, Advanced Manufacturing Technology Research Group, University of Baghdad, Baghdad, Iraq

    Ahmed R. J. Almusawi

Authors
  1. Hassan J. Khaudair
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Adnan A. Ugla
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Ahmed R. J. Almusawi
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Hassan J. Khaudair.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Khaudair, H.J., Ugla, A.A. & Almusawi, A.R.J. Design, Integrating and Controlling of Mig-Based Shaped Metal Deposition System with Externally Cold Wire Feed in Additive Layered Manufacturing Technology. Arab J Sci Eng 46, 2677–2690 (2021). https://doi.org/10.1007/s13369-020-05100-6

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s13369-020-05100-6

Keywords

Search

Navigation