Additive manufacturing is becoming widely used today. However, quality, efficiency, and cost limit the widespread adoption and mass production in the industry. A hybrid approach combines in-site rolling and machining with WAAM named hybrid casting forging and milling(HCFM) was proposed to bridge this gap. Micro-roller moves synchronously behind the welding torch and applies a continuous pressure on the top surface to deform the semi-solid zone. Milling is coupled for better geometrical accuracy, surface finish, defects removing and complex geometries or internal features.
Numerous forging components including titanium alloy aeronautical parts, stainless steel propeller, aluminium alloy beam, aero-engine transition section and austenite-bainite steel high-speed rail frog have been manufactured of high quality by this technology. This technology offers an innovative way of simplified, efficient and green manufacturing with one piece of integrated equipment producing high performance forging components as its output. HCFM equipments will be provided soon.