Proposition of a model to determine the process parameters for manufacturing thick parts with WAAM technology

Figures & data

Figure 1. Example of a part with a variable section width.

Figure 2. Part typology classification.

Figure 3. Classical filling strategies.

Figure 4. A selection parameter model for WAAM by Quérard (2019).

Table 1. Synthesis of existing parameter selection methods.

Article	Methodology	Application	Conclusion
Quérard (2019)	Based on experimentation	Thin and massive wall	- Generic method that can be used as a basis
Cui et al. (2021)	Selection of the manufacturing parameters based on heat input	Massive and wall with a constant width	- Application not appropriate
Zhao et al. (2020)	Selection of the manufacturing parameters based on heat input (temperature prediction of the next layer)	Part with a width smaller than bead width	- Application not appropriate
Xia et al. (2020)	Selection of the manufacturing parameters based on the vision-based feedback	Thin wall	- Application not appropriate
Ferreira et al. (2022)	Based on trajectory simulation and experimentation to compare different filling strategies	Massive, part with a variable width	- zigzag filling strategy can be applied - Don’t have a selection of the manufacturing parameters method

Figure 5. Initial model to make a choice of the process parameters.

Various experiments have been made using the parameters issued from this initial model.

Figure 6. Strategy with mono-bead and zigzag filling.

Figure 7. Strategy 2 with zigzag filling all along the part.

Figure 8. Results of both strategies with two layers.

Figure 9. Prototype with eight layers.

Figure 10. Proposed model of parameters choice.

Figure 11. Top view of the part.

Table 2. Experimentation design to determine the function between torch speed and bead length.

D_bead(mm) TS(cm/s)	5	10	15
4	A1(dz_A1)	A2(dz_A2)	A3(dz_A3)
4.5	B1(dz_B1)	B2(dz_B2)	B3(dz_B3)
5	C1(dz_C1)	C2(dz_C2)	C3(dz_C3)
6	D1(dz_D1)	D2(dz_D2)	D3(dz_D3)
7	E1(dz_E1)	E2(dz_E2)	E3(dz_E3)
8	F1(dz_F1)	F2(dz_F2)	F3(dz_F3)
9	G1(dz_G1)	G2(dz_G2)	G3(dz_G3)
9.5	H1(dz_H1)	H2(dz_H2)	H3(dz_H3)
10	I1(dz_I1)	I2(dz_I2)	I3(dz_I3)
10.5	J1(dz_J1)	J2(dz_J2)	J3(dz_J3)

Table 3. Average height of a layer (mm) based on TS and D_bead.

D_bead(mm) TS(cm/s)	5	10	15
4	5.45	6.25	6.6.
4.5	5.40	6.20	6.55
5	5.27	6.05	6.45
6	4.94	5.73	6.10
7	4.35	5.04	5.50
8	3.91	4.56	4.96
9	3.54	4.10	4.60
9.5	3.45	3.96	4.40
10	3.35	3.90	4.30
10.5	3.30	3.81	4.20

Figure 12. Relation between dz_average and travel speed.

Figure 13. Response surface.

D_bead = 5.3 TS² − 88TS+375

Figure 14. Function between TS and D_bead.

Figure 15. Prototype manufactured with calculated TS.

Figure 16. Comparison between two prototypes.

Quérard, V. Réalisation de pièces aéronautiques de grandes dimensions par fabrication additive WAAM. Diss. 2019.

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