A Comparative Study of Two WAAM Patterns for Structures with Grid Fin Characteristics

Area of Science:

• Aerospace Engineering
• Materials Science
• Manufacturing Technology

Background:

• Grid fins are critical aerospace components.
• Wire Arc Additive Manufacturing (WAAM) offers time and cost efficiencies for large-scale component production compared to traditional methods.
• Welding strategies significantly impact the quality of additively manufactured parts.

Purpose of the Study:

• To evaluate the feasibility of two distinct WAAM printing orientations (horizontal 'lie' (L) and perpendicular 'stand' (S)) for grid fin manufacturing.
• To analyze the impact of printing orientation on surface quality, microstructure, and mechanical properties.
• To simulate and analyze thermal and mechanical stresses during the WAAM process for both orientations.

Main Methods:

• Investigated two WAAM printing orientations: horizontal (L) and perpendicular (S) on a small-scale grid fin model.
• Evaluated surface quality, microstructure, and mechanical properties at weld junctions.
• Employed Finite Element Analysis (FEA) to simulate temperature distribution, deformation, and stress profiles.

Main Results:

• The horizontal (L) mode proved easily manufacturable with stable properties.
• The perpendicular (S) mode demonstrated potential for market application, contingent on welding parameter optimization.
• FEA provided insights into thermal and mechanical behaviors associated with each printing strategy.

Conclusions:

• Both WAAM printing orientations have implications for grid fin manufacturing.
• The horizontal (L) mode is a viable option for stable production.
• The perpendicular (S) mode presents significant future potential with further research and optimization of welding parameters.