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Meeting 11th Conference on Trends in Welding Research + Additive Manufacturing (TWR+AM)
Symposium 11th Conference on Trends in Welding Research + Additive Manufacturing (TWR+AM)
Presentation Title Assessment of Wire Arc Additive Manufacturing (WAAM) for the Production of ER420 Cutting Dies
Author(s) Edmundo Benedetti Filho, Louriel Oliveira Vilarinho, Gabriel Vicente Rosa, Victor Eduardo Silva Alves
On-Site Speaker (Planned) Edmundo Benedetti Filho
Abstract Scope Wire Arc Additive Manufacturing (WAAM) stands out among metal additive techniques for its high deposition rates (2–15 kg/h), cost efficiency, and ability to produce large, complex metallic components with structural integrity. This study evaluates WAAM’s potential for on-demand tooling, specifically high-hardness cutting dies. A die was fabricated using ER110S-1 low-alloy steel for the base and ER420 martensitic stainless steel for the cutting edge. The as-printed component achieved 650 HV surface hardness and successfully cut 5,000 gaskets without post-deposition heat treatment, matching the performance of conventional AISI D2 tool steel dies. This eliminated thermal processing, reducing lead time and costs. As industrial WAAM adoption remains nascent—particularly in tooling—this case provides valuable evidence of its technical viability, cost-effectiveness, and environmental benefits over traditional subtractive or formative methods.
Proceedings Inclusion? Undecided

OTHER PAPERS PLANNED FOR THIS SYMPOSIUM

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AI-Driven Additive Friction Stir Deposition: Revealing Process Physics for Superior Performance
Alloy Design for Improved Precipitation Hardening in Additively Manufactured Al-Alloys
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An Engineering Approach for Weld Creep Lifetime Assessment Based on Local Property Measurement
An Expansible Machine Learning Framework for Enhancing Resistance Spot Welding
Analysis of Low Transformation Temperature Welding Consumables- Distortion Control and Evolution of Stresses
Approaching Infrastructure-Scale Additive Manufacturing for the Power Industry with Project Rapid RUNNERS
Art of AM, Pushing the Welding Boundaries
Assessing Accuracy of Solidification Cracking Criteria for Fusion Welding of High-Strength Aluminum in Houldcroft Weldability Test
Assessment of Wire Arc Additive Manufacturing (WAAM) for the Production of ER420 Cutting Dies
Comparison Between Single-Wire and Tandem WAAM for ASME B16.5 Flange Manufacturing
Controlling Interfacial Resolidification in Impact-Based Additive Manufacturing for Defect-Free Joining of Dissimilar Alloys
DED Arc Additive Solution -Fronius Cold Metal Transfer
Deep Learning Based System for Real-time Arc Welding Monitoring
Developing a Robust Friction Self-piercing Riveting Process for AA7075-AA7075–AA6022 3T Stack with a Thin Bottom Sheet Under Varied Manufacturing Conditions
Development of a New and Simple Solid-state Additive Manufacturing Method
Diffusion Braze Repairs of Stationary Gas Turbine Engine Components, Past, Present and Future
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Dissimilar Metal Laser Welding of 304L Stainless Steel and Ti-6Al-4V with Vanadium Directed Energy Deposition Interlayers
DR-Weld: Fast, Scalable Simulation for Large-Scale Welding and Metal Additive
Effect of Welding Process-Induced Thermo-Mechanical Cycling on Ductility Dip Cracking in Welds of High-Cr Ni-base Filler Metals
Electroslag Additive Manufacturing: A Pathway for High Throughput Near Net Shape Production
Exploratory Analysis of the Impact of Chemical Variations on the Predicted Solidification Cracking Susceptibility of Nickel Alloys
Extended CCT Diagram for Rapid Microstructure Formation in L-DED of 420 Stainless and Grade 91 Steels
From Applicable Machine Learning to Generalizable AI in Welding: Bridging Lab–Plant Gaps Across Machines and Applications
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High-Temperature Material Databases for Navy Structural Steels
How Deep Learning and Generative AI Advance Intelligent Welding Manufacturing
Hybrid Laser Arc Welding Process Optimization to Mitigate Stress Corrosion Cracking in Dry Storage Canisters
Improvement of the Fatigue Strength Through Machining Process in Stainless Steel Welds
Improving Fidelity of Residual Stress and Distortion Prediction for Welding and AM – Importance of Plasticity
In-Situ Monitoring of Weld Pool Dimensions and Estimation of Cooling Rates to Enable Feedback Control and Non-Destructive Evaluation
Interfacial Contact and Compliance Govern Keyhole Stability in Multilayer Foil Laser Welding
Investigating the Large Scale Wire Arc Additive Manufacturability of Super Duplex Stainless Steel: Microstructure and Mechanical Behavior Perspectives
Investigation of Microstructure, Crystallographic texture, and Improvement of Mechanical Properties of Nb Modified 312 LSi Stainless Steel (with Addition of 2%Nb) Manufactured Via (WAAM)
Key Learnings in Additive Welding of Super Duplex Stainless Steel in Pressure Vessel Application
Laser Powder Bed Fusion Alloy 625 Gas Tungsten Arc Weld Heat Affected Zone Microcracking
Laser Powder Bed Fusion of Group VI Transition Metals
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Linking Extended CCT Diagrams with In Situ Infrared Thermography for Spatially Resolved Phase Transformation Mapping in Additively Manufactured 410 Stainless Steel
Mechanics of the Solid-State Bonding Under Severe Thermomechanical Processes
Microstructural Evolution and Creep Performance of SA516 Weldments by High-temperature High-pressure Hydrogen Attack
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Nondestructive Testing of Additive Manufactured Aerospace Components
On the Use of Event-Based Change Detection Neuromorphic Imagers for In-Process Monitoring of Additive Manufacturing
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Prediction of Thermally Affected Region in Keyhole Mode Laser Welding of Copper Through Sequentially-Coupled Molten Pool and Thermo-Mechanical Simulations
Process-Based Qualification in the Age of Artificial Intelligence: Are We There Yet?
Process–Structure–Property–Performance Relationships in Wire Arc Additive Manufacturing of Refractory alloy based Multi-Material Structures
Process Control in Multi-Material Tandem Wire-Arc Directed Energy Deposition of Functionally Graded Steels
Residual Stresses and Distortion: Welding Vs. Metal AM — Shared Physics with New Twists
Revealing High-Temperature Hydrogen Attack Mechanisms in SA516 Grade 70 Carbon Steel and Its Weldments Using an Integrated Experimental Approach
Robotic Wire Arc Additive Manufacturing of 316L Stainless Steel for Forging Preforms
Simulating Residual Stress and Distortion in Part-Scale – Fusion Welding and Metal Additive Manufacturing
State-of-the-Art Review of Additive Friction Stir Deposition: Fundamentals, Variants, Supply Chain Opportunities, and Future Directions
The Future is Now: Handheld Laser Beam Welding and the Revolution Under Way
Understanding and Addressing the Challenges of Laser Beam Welding in Space
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