Additive Manufacturing: Large-Scale Metal Additive Manufacturing: Advanced Manufacturing Process
Program Organizers: Yousub Lee, Oak Ridge National Laboratory; Antonio Ramirez, Ohio State University; Yashwanth Bandari, 'Meltio Inc.; Duckbong Kim, Tennessee Technological University; Wei Zhang, Ohio State University
Wednesday 8:00 AM
October 20, 2021
Room: A114
Location: Greater Columbus Convention Center
Session Chair: Duckbong Kim, Tennessee Technological University
8:00 AM
Manufacturing Large Scale Metal Parts via AM – Current and Future Directions: Andrzej Nycz1; 1Oak Ridge National Laboratory
Additive manufacturing opens new ways of producing metal parts. However, not every AM metal technology is equally suitable for objects larger than 2ft in the long axis. Furthermore, the need to scale the technologies for parts 10-fold larger creates a new set of challenges. On the other hand, the lack of legacy methods and necessity for backward compatibility allows for new unrestricted designs and solutions. This talk will present the current capabilities and future directions using wire-arc technology as an example.
8:40 AM
An Investigation of the Properties of Stamping Tool Inserts Manufactured Using a Novel Wire Deposition Additive Manufacturing Process: Joy Forsmark1; Alan Gillard1; Sal Barriga2; Adam LaDelpha2; Henry Merrow2; Brian McCabe2; 1Ford Motor Company; 2Digital Alloys
Additive manufacturing is an emerging family of technologies that has the potential to provide great design flexibility for the automotive industry. One area of investigation is in the use of this technology for automotive tooling applications. Wire direct energy deposition (DED) technology has the potential to deliver unique design features in a near-net shape geometry, such as conformal cooling and multi-material strategies, while providing significantly reduced delivery time compared with conventional tooling insert manufacturing. However, resolution and quality can be challenging. This paper will present a preliminary investigation of a novel wire-based technology that uses resistive heating to power the deposition. This new technology was used to produce inserts for sheet metal stamping tooling. Inserts with geometric features of interest were produced and the mechanical properties, microstructures, and functional capability were assessed. The feasibility of printing stamping tool inserts was demonstrated and initial functional targets were met.
9:00 AM
Now On-Demand Only - Development of 3D Metal Printing for Toolmaking: Felix Gemse1; Danny Lubosch2; Olaf Penning3; Edgar Fries4; Enrico Danz5; 1Günter-Köhler-Institute GmbH; 2Gefertec GmbH; 3Hermann Fliess & Co. GmbH; 4Fraunhofer Institute for Production Systems and Design Technology IPK ; 5SWM Werkzeugfabrik GmbH & Co.KG
As part of an ongoing research project, an alloy adapted for arc-based 3D metal printing 3DMP ® will be developed, which will enable a more economical production of mold tools and stamping tools. Whereby the time, cost and resource requirements can be significantly reduced. To achieve this goal, commercially available reference materials were defined and tested for their properties using sample geometries standardized throughout project. Based on the first investigations an adapted alloy composition was manufactured as cored filler wire and tested for applicability. As the project progresses, the final alloy is iteratively approximated. On the way to this goal, hardness field measurements, tensile tests, as well as customized testing methods on edge stability are carried out in order to compare the different materials. The project will be completed with the 3D metal printing of a punching device for forged wrenches.
9:20 AM
Hybrid Metal Manufacturing of Large Freeform Geometries: Bradley Jared1; William Hamel1; Tony Schmitz1; Joshua Penney1; Leah Jacobs1; Aaron Cornelius1; Jake Dvorak1; Michael Buckley1; Greg Corson1; Eduardo Miramontes1; 1University of Tennessee, Knoxville
The timely fabrication of large, complex metallic structures is a persistent challenge for America’s industrial base. Delivery schedules for large parts, i.e one to two feet cube and larger, are routinely defined in months and years; introducing unacceptable risk and cost for most products. On-going work is addressing these challenges through the development of a large-scale hybrid metal manufacturing system which combines multi-material metal inert gas (MIG) deposition, structured light-scanning metrology, part handling and five-axis machining. The resulting deposition-metrology-machining process cycle introduces design opportunities for complex, multi-material part topographies. The integration, capabilities and challenges of the system will be demonstrated through the processing of mild steel and nickel-aluminum-bronze structures. Progress in control of each process and overall integration will be presented, and the coupling influences across them highlighted. Potential implications and needs for future part quality and certification / qualification will also be discussed.
9:40 AM
Novel Thermal Management Technique for Additive Manufacturing: Robert Griffiths1; David Garcia2; Hang Yu1; 1Virginia Polytechnic Institute; 2Pacific Northwest National Laboratory
Critical for large-scale additive manufacturing, minimizing thermal gradients helps prevent expansion mismatch and subsequent residual stress, warpage, and common printing defects. Fundamentally, this can be achieved by either reducing the peak temperature or increasing the bottom temperature during deposition, however in practice these changes are limited due to process and material behavior. Here, we discuss a newly patented thermal management technology suitable for fusion-based and solid-state additive manufacturing techniques. This environmental control technology adjusts the temperature of the part on a layer-by-layer basis, enabling better control of thermal gradients, and makes it compatible with most additive processes. In addition to mitigating thermal gradients, the thermal control allows for in-situ heat treatment, controlled part shrinkage, potentially expanding the suite of usable materials in AM, as well as improving material quality and contributing to consistent additive manufacturing part performance.
10:00 AM
High Deposition Rate Wire Arc Directed Energy Deposition of 316L for Pressure Retaining Components in Nuclear Applications: Luc Hagen1; Stephen Tate2; Zhenzhen Yu1; Jonah Klemm-Toole1; 1Colorado School of Mines; 2EPRI
The use of wire-arc directed energy deposition (WA-DED) or wire arc additive manufacturing (WAAM) is being considered as a fabrication method for pressure components within nuclear power plants. This would allow for onsite construction of replacement parts, decreasing plant down time and preventing millions of dollars in losses. However, updates to ASME code are needed to use WA-DED to construct large 316L stainless steel pressure retaining components. In this presentation, we discuss our work using a high deposition rate pulsed spray transfer weld mode to construct demonstration builds with both 316L and 316L Si wire. A design of experiments was used to study the effects of inter-pass temperature, weld speed, and wire composition on microstructure evolution and mechanical properties. We discuss how the results obtained in these demonstration experiments help inform the selection of processing parameters for building a large (> 200 lb) pressure retaining valve body.