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Sustainable hybrid manufacturing of AlSi5 alloy turbine blade prototype by robotic direct energy layered deposition and subsequent milling : an alternative to selective laser melting?
ID
Dugar, Jaka
(
Avtor
),
ID
Ikram, Awais
(
Avtor
),
ID
Klobčar, Damjan
(
Avtor
),
ID
Pušavec, Franci
(
Avtor
)
PDF - Predstavitvena datoteka,
prenos
(13,54 MB)
MD5: 51D8AEE0701171613A5430D4E97C9BC6
URL - Izvorni URL, za dostop obiščite
https://www.mdpi.com/1996-1944/15/23/8631
Galerija slik
Izvleček
Additive technologies enable the flexible production through scalable layer-by-layer fabrication of simple to intricate geometries. The existing 3D-printing technologies that use powders are often slow with controlling parameters that are difficult to optimize, restricted product sizes, and are relatively expensive (in terms of feedstock and processing). This paper presents the development of an alternative approach consisting of a CAD/CAM + combined wire arc additive-manufacturing (WAAM) hybrid process utilizing the robotic MIG-based weld surfacing and milling of the AlSi5 aluminum alloy, which achieves sustainably high productivity via structural alloys. The feasibility of this hybrid approach was analyzed on a representative turbine blade piece. SprutCAM suite was utilized to identify the hybrid-manufacturing parameters and virtually simulate the processes. This research provides comprehensive experimental data on the optimization of cold metal transfer (CMT)–WAAM parameters such as the welding speed, current/voltage, wire feed rate, wall thickness, torch inclination angle (shift/tilt comparison), and deposit height. The multi-axes tool orientation and robotic milling strategies, i.e., (a) the side surface from rotational one-way bottom-up and (b) the top surface in a rectangular orientation, were tested in virtual CAM environments and then adopted during the prototype fabrication to minimize the total fabrication time. The effect of several machining parameters and robotic stiffness (during WAAM + milling) were also investigated. The mean deviation for the test piece’s tolerance between the virtual processing and experimental fabrication was −0.76 mm (approx.) at a standard deviation of 0.22 mm assessed by 3D scanning. The surface roughness definition Sa in the final WAAM pass corresponds to 36 µm, which was lowered to 14.3 µm after milling, thus demonstrating a 55% improvement through the robotic comminution. The tensile testing at 0° and 90° orientations reported fracture strengths of 159 and 161.3 MPa, respectively, while the yield stress and reduced longitudinal (0°) elongations implied marginally better toughness along the WAAM deposition axes. The process sustainability factors of hybrid production were compared with Selective Laser Melting (SLM) in terms of the part size freedom, processing costs, and fabrication time with respect to tight design tolerances. The results deduced that this alternative hybrid-processing approach enables an economically viable, resource/energy feasible, and time-efficient method for the production of complex parts in contrast to the conventional additive technologies, i.e., SLM.
Jezik:
Angleški jezik
Ključne besede:
computer-aided manufacturing
,
computer-aided design
,
hybrid processing
,
robotic milling
,
design for additive manufacturing
,
wire arc additive manufacturing
,
CAD
,
CAM
,
WAAM
,
DFAM
Vrsta gradiva:
Članek v reviji
Tipologija:
1.01 - Izvirni znanstveni članek
Organizacija:
FS - Fakulteta za strojništvo
Status publikacije:
Objavljeno
Različica publikacije:
Objavljena publikacija
Leto izida:
2022
Št. strani:
39 str.
Številčenje:
Vol. 15, iss. 23, art. 8631
PID:
20.500.12556/RUL-144948
UDK:
621.9:658.5:004.4
ISSN pri članku:
1996-1944
DOI:
10.3390/ma15238631
COBISS.SI-ID:
146512387
Datum objave v RUL:
24.03.2023
Število ogledov:
513
Število prenosov:
93
Metapodatki:
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Objavi na:
Gradivo je del revije
Naslov:
Materials
Skrajšan naslov:
Materials
Založnik:
Molecular Diversity Preservation International
ISSN:
1996-1944
COBISS.SI-ID:
33588485
Licence
Licenca:
CC BY 4.0, Creative Commons Priznanje avtorstva 4.0 Mednarodna
Povezava:
http://creativecommons.org/licenses/by/4.0/deed.sl
Opis:
To je standardna licenca Creative Commons, ki daje uporabnikom največ možnosti za nadaljnjo uporabo dela, pri čemer morajo navesti avtorja.
Sekundarni jezik
Jezik:
Slovenski jezik
Ključne besede:
računalniško podprta proizvodnja
,
računalniško podprto projektiranje
,
hibridna predelava
,
robotsko frezanje
,
zasnova za dodajalno proizvodnjo
,
izdelava dodajalne tehnologije z varjenjem
Projekti
Financer:
ARRS - Agencija za raziskovalno dejavnost Republike Slovenije
Številka projekta:
L2-8184
Naslov:
Razvoj in implementacija kriogenega odrezavanja v serijsko proizvodnjo za povečanje produktivnosti procesov vrtanja in frezanja
Financer:
ARRS - Agencija za raziskovalno dejavnost Republike Slovenije
Številka projekta:
L2-1836
Naslov:
Razvoj in implementacija inovativne tehnologije obdelave ZnO keramike z definirano rezalno geometrijo v serijsko proizvodnjo za povečanje kakovosti varistorjev kot končnih izdelkov
Financer:
ARRS - Agencija za raziskovalno dejavnost Republike Slovenije
Številka projekta:
P2-0266
Naslov:
Napredne izdelovalne tehnologije za visokokakovostno in trajnostno proizvodnjo
Financer:
ARRS - Agencija za raziskovalno dejavnost Republike Slovenije
Številka projekta:
P2-0270
Naslov:
Proizvodni sistemi, laserske tehnologije in spajanje materialov
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