Coordinate system setting for post-machining of impeller shape by wire arc DED and evaluation of processing...

Area of Science:

• Materials Science and Engineering
• Manufacturing Processes
• Additive Manufacturing

Background:

• Wire arc additive manufacturing (WAAM) is a direct energy deposition (DED) process utilizing arc welding for metal part fabrication.
• WAAM excels at producing large, complex metal components quickly but often requires significant post-processing due to surface irregularities and dimensional errors.
• Impellers, critical components in fluid delivery systems, present manufacturing challenges due to their complex geometry and high material waste during conventional machining.

Purpose of the Study:

• To develop and validate a Wire arc additive manufacturing (WAAM) process for producing a 160 mm diameter impeller.
• To optimize manufacturing parameters for both productivity and quality in WAAM impeller fabrication.
• To integrate post-processing steps, including robot and tool path design, to minimize errors and enhance overall process reliability.

Main Methods:

• Additive manufacturing of a 6-bladed fan-type impeller using Inconel 625 alloy wire via WAAM.
• Experimental determination of optimal manufacturing conditions balancing productivity and quality.
• Design of robot and tool paths for post-processing, focusing on reducing coordinate system errors during workpiece handling.

Main Results:

• Successful additive manufacturing of a 160 mm diameter Inconel 625 impeller using the developed WAAM process.
• Identification of manufacturing parameters ensuring both high productivity and desired product quality.
• Demonstrated reduction in process coordinate system errors through optimized post-processing path planning.

Conclusions:

• The WAAM process, when optimized and integrated with intelligent post-processing, offers a viable and efficient method for manufacturing complex impellers.
• The study verified improved production efficiency and process reliability compared to conventional manufacturing methods.
• This research highlights the potential of WAAM for high-value components where complex geometry and material efficiency are crucial.