Development and Experimental Investigation of the TIG Based Wire and Arc Additive Manufacturing WAAM Process for Metal Deposition

Abstract

The utilization of Wire Arc based additive manufacturing has increased in aerospace newlineindustries and for medical implants. The additive manufacturing of metallic parts is commonly done by laser-based processes using powder as a raw material. However, such processes require more initial investment. In addition, the parts produced using powder requires high specific energy and have less density as compared to the parts produced by wire. The wire arc additive manufacturing (WAAM) process with welding source utilizes an arc to provide higher deposition rates, high part density, lower power consumption and low initial investment cost over laser and other commercial sources. To meet customized product demand WAAM has potential to present a better alternative than conventional manufacturing processes like casting and machining in terms of cleaner and sustainable process. The literature review available on the WAAM processes showed that most of the researchers worked on GMAW welding based WAAM process due to its ease in synchronizing welding source and wire feeding nozzle. The higher deposition rates in GMAW based WAAM process helps in producing larger size workpieces. However, GMAW welding based process reports less dimensional accuracy and higher spattering defects. Therefore, it has been realized to increase the dimensional accuracy in the metal deposition with lower spattering defects and without compromising the deposition rate. It can be achieved by designing a GTAW welding based additive manufacturing system. This has improved the dimensional accuracy in the metal newlinedeposition, mechanical properties, better surface appearance and lesser spattering defects. In this research work a Gas Tungsten Arc Welding (GTAW) based semi-automatic newlineadditive manufacturing system has been designed. The Programable Logic Controller (PLC) v based advanced control system has been designed for smooth control of the deposition system. The fabrication work of this system was done in-house at BITS-Pilani, India.