Wire Arc Additive Manufacturing: Difference between revisions
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=Basics= | =Basics= | ||
*This is a 3D Printing Method similar to Plastic FDM, but using | *A Subcategory of [[Directed Energy Deposition Additive Manufacturing]] | ||
* | *This is a 3D Printing Method similar to Plastic FDM, but using a [[Wire Fed Arc Welder]] (Either [[GMAW]] or [[GTAW]] ) | ||
*MIG welder is a fast and cost effective for additive manufacturing of complex geometries. | |||
=OSE Context= | =OSE Context= | ||
Wire arc allows low feestock cost 3D metal printing of large parts. A spool of MIG wire is $1.15/lb in bulk -[https://weldingsupply.com/cgi-bin/einstein.pl?PNUM::1:UNDEF:X:70S603544]. This is relevant to 3D printing towers for wind turbines, see [[3D Printed Windmill Tower]], or 3D printing entire tractor frames. | Wire arc allows low feestock (also non-[[Pyrophoric]] unlike some [[Metal Powders]] ) cost 3D metal printing of large parts. A spool of MIG wire is $1.15/lb in bulk -[https://weldingsupply.com/cgi-bin/einstein.pl?PNUM::1:UNDEF:X:70S603544]. This is relevant to 3D printing towers for wind turbines, see [[3D Printed Windmill Tower]], or 3D printing entire tractor frames. | ||
=Mig Welder | =Mig Welder Cost Calculations= | ||
Cost of shielding gas is $9/8 hour shift, about $1/hour. Deposition rates go up to 20 lb per hour. See [[Welding Deposition Rate]]. This means one spool is used up per 2 hours. $46 in metal, $2 in gas. So about 4% is shielding gas. | Cost of shielding gas is $9/8 hour shift, about $1/hour. Deposition rates go up to 20 lb per hour. See [[Welding Deposition Rate]]. This means one spool is used up per 2 hours. $46 in metal, $2 in gas. So about 4% is shielding gas. | ||
=Examples/Industry Standards= | =Examples/Industry Standards= | ||
#Cranfield University is doing work on WAAM. Largest printed part - 6 meters long, 300lb, plain aluminum - [https://waammat.com/blog/have-we-3d-printed-the-biggest-metal-part-ever]. See their presentation - good insight - [https://waammat.com/documents/s-williams-large-scale-metal-wire-arc-additive-manufacturing-of-structural-engineering-parts]. They are making real structural parts. | |||
#Australian government funds $376k for WAAM - [https://3dprintingindustry.com/news/australian-government-awards-376200-commercialize-wire-arc-additive-manufacturing-117893/] | |||
#3D Printed Bridge - [https://www.dezeen.com/2018/10/22/worlds-first-3d-printed-steel-bridge-completed-mx3d-technology/] | |||
=See Also= | =See Also= | ||
| Line 20: | Line 21: | ||
*[[Open Source MIG Welder]] | *[[Open Source MIG Welder]] | ||
= | =Product Development Strategy= | ||
*[[1" Universal Axis]] + [[Universal Frame]] + [[Universal Controller]]. | |||
*3 prototypes in 3 months of full time work we can nail this to product-level | |||
*considering putting such into our budget surrounding the [[Seed Home 2]] | |||
*Steel angle frame - rapid prototype uses 3D printed corners for holding - then welded together. Essentially - 3D printed corners are a jig for frame build. | |||
*Use counterweighted platform, and do up to 200 lb prints. Counterweight considers Weight of platform + 100 lb, so 200 lb print would have 100 lb imbalance for safety factor 2 on 200 lb hold of motors. Platform should lift a person. | |||
*All belts and sensitive parts are fully shielded | |||
*Water or air cooling for platform as needed, and using insulated platform | |||
*Hire a competent engineer at $50/hr. | |||
*Budget - $24k + materials. | |||
=Internal Links= | |||
*[[Filler Rod]] | |||
*Probably should merge these two? : | |||
**[[Welding Wire]] | |||
**[[Welder Wire]] | |||
=External Links= | |||
*[https://www.ramlab.com/resources/ded-101/ A Page by "RAMLAB" Titled "Directed Energy Deposition 101" ] (This goes over all forms and their advantages/disadvantages etc, also mentions [[EBM]] / [[LBM]] ) | |||
*Laser + TIG setup? - https://www.addere.com/addere-i | *Laser + TIG setup? - https://www.addere.com/addere-i | ||
*Electron beam and laser beam can be used - [http://www.sciaky.com/additive-manufacturing/wire-am-vs-powder-am] | *Electron beam and laser beam can be used - [http://www.sciaky.com/additive-manufacturing/wire-am-vs-powder-am] | ||
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*Review paper on Wire Arc Additive Mfg - WAAM - '''"The paper concludes that WAAM is a promising alternative to traditional subtractive manufacturing for fabricating large expensive metal components. '''[https://link.springer.com/chapter/10.1007/978-981-10-5355-9_1] | *Review paper on Wire Arc Additive Mfg - WAAM - '''"The paper concludes that WAAM is a promising alternative to traditional subtractive manufacturing for fabricating large expensive metal components. '''[https://link.springer.com/chapter/10.1007/978-981-10-5355-9_1] | ||
*Companies producing cold weld spray 3d printing - [https://www.spee3d.com/about/] | *Companies producing cold weld spray 3d printing - [https://www.spee3d.com/about/] | ||
*Metal arc from Prodways? - [https://3dprintingindustry.com/news/prodways-shipping-first-rapid-additive-forging-3d-printer-130767/]. They call it forging, but it appears to be simple welding with shielding gas ( | *Metal arc from Prodways? - [https://3dprintingindustry.com/news/prodways-shipping-first-rapid-additive-forging-3d-printer-130767/]. They call it forging, but it appears to be simple welding with shielding gas (GMAW) | ||
*WAAM article - [https://www.3dprintingmedia.network/lets-talk-waam-wire-arc-additive-manufacturing/] | *WAAM article - [https://www.3dprintingmedia.network/lets-talk-waam-wire-arc-additive-manufacturing/] | ||
[[Category: 3D Printing]] [[Category: Welding]] | |||
Latest revision as of 00:38, 28 October 2022
This is 3D printing using the deposition of metal with MIG welders using standard MIG wire and automated computer controlled motion systems..
Basics
- A Subcategory of Directed Energy Deposition Additive Manufacturing
- This is a 3D Printing Method similar to Plastic FDM, but using a Wire Fed Arc Welder (Either GMAW or GTAW )
- MIG welder is a fast and cost effective for additive manufacturing of complex geometries.
OSE Context
Wire arc allows low feestock (also non-Pyrophoric unlike some Metal Powders ) cost 3D metal printing of large parts. A spool of MIG wire is $1.15/lb in bulk -[1]. This is relevant to 3D printing towers for wind turbines, see 3D Printed Windmill Tower, or 3D printing entire tractor frames.
Mig Welder Cost Calculations
Cost of shielding gas is $9/8 hour shift, about $1/hour. Deposition rates go up to 20 lb per hour. See Welding Deposition Rate. This means one spool is used up per 2 hours. $46 in metal, $2 in gas. So about 4% is shielding gas.
Examples/Industry Standards
- Cranfield University is doing work on WAAM. Largest printed part - 6 meters long, 300lb, plain aluminum - [2]. See their presentation - good insight - [3]. They are making real structural parts.
- Australian government funds $376k for WAAM - [4]
- 3D Printed Bridge - [5]
See Also
Product Development Strategy
- 1" Universal Axis + Universal Frame + Universal Controller.
- 3 prototypes in 3 months of full time work we can nail this to product-level
- considering putting such into our budget surrounding the Seed Home 2
- Steel angle frame - rapid prototype uses 3D printed corners for holding - then welded together. Essentially - 3D printed corners are a jig for frame build.
- Use counterweighted platform, and do up to 200 lb prints. Counterweight considers Weight of platform + 100 lb, so 200 lb print would have 100 lb imbalance for safety factor 2 on 200 lb hold of motors. Platform should lift a person.
- All belts and sensitive parts are fully shielded
- Water or air cooling for platform as needed, and using insulated platform
- Hire a competent engineer at $50/hr.
- Budget - $24k + materials.
Internal Links
- Filler Rod
- Probably should merge these two? :
External Links
- A Page by "RAMLAB" Titled "Directed Energy Deposition 101" (This goes over all forms and their advantages/disadvantages etc, also mentions EBM / LBM )
- Laser + TIG setup? - https://www.addere.com/addere-i
- Electron beam and laser beam can be used - [6]
- Is hot wire TIG used for 3D printing?
- TIG additive - Korea - [7]
- Paper on cold and hot wire TIG - [8]
- RepRap metal printer with TIG - [9]
- StrongPrint TIG with wire feed - [10]
- Review paper on Wire Arc Additive Mfg - WAAM - "The paper concludes that WAAM is a promising alternative to traditional subtractive manufacturing for fabricating large expensive metal components. [11]
- Companies producing cold weld spray 3d printing - [12]
- Metal arc from Prodways? - [13]. They call it forging, but it appears to be simple welding with shielding gas (GMAW)
- WAAM article - [14]