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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
(
Author
),
ID
Ikram, Awais
(
Author
),
ID
Klobčar, Damjan
(
Author
),
ID
Pušavec, Franci
(
Author
)
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MD5: 51D8AEE0701171613A5430D4E97C9BC6
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https://www.mdpi.com/1996-1944/15/23/8631
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Abstract
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.
Language:
English
Keywords:
computer-aided manufacturing
,
computer-aided design
,
hybrid processing
,
robotic milling
,
design for additive manufacturing
,
wire arc additive manufacturing
,
CAD
,
CAM
,
WAAM
,
DFAM
Work type:
Article
Typology:
1.01 - Original Scientific Article
Organization:
FS - Faculty of Mechanical Engineering
Publication status:
Published
Publication version:
Version of Record
Year:
2022
Number of pages:
39 str.
Numbering:
Vol. 15, iss. 23, art. 8631
PID:
20.500.12556/RUL-144948
UDC:
621.9:658.5:004.4
ISSN on article:
1996-1944
DOI:
10.3390/ma15238631
COBISS.SI-ID:
146512387
Publication date in RUL:
24.03.2023
Views:
533
Downloads:
93
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Record is a part of a journal
Title:
Materials
Shortened title:
Materials
Publisher:
Molecular Diversity Preservation International
ISSN:
1996-1944
COBISS.SI-ID:
33588485
Licences
License:
CC BY 4.0, Creative Commons Attribution 4.0 International
Link:
http://creativecommons.org/licenses/by/4.0/
Description:
This is the standard Creative Commons license that gives others maximum freedom to do what they want with the work as long as they credit the author.
Secondary language
Language:
Slovenian
Keywords:
računalniško podprta proizvodnja
,
računalniško podprto projektiranje
,
hibridna predelava
,
robotsko frezanje
,
zasnova za dodajalno proizvodnjo
,
izdelava dodajalne tehnologije z varjenjem
Projects
Funder:
ARRS - Slovenian Research Agency
Project number:
L2-8184
Name:
Razvoj in implementacija kriogenega odrezavanja v serijsko proizvodnjo za povečanje produktivnosti procesov vrtanja in frezanja
Funder:
ARRS - Slovenian Research Agency
Project number:
L2-1836
Name:
Razvoj in implementacija inovativne tehnologije obdelave ZnO keramike z definirano rezalno geometrijo v serijsko proizvodnjo za povečanje kakovosti varistorjev kot končnih izdelkov
Funder:
ARRS - Slovenian Research Agency
Project number:
P2-0266
Name:
Napredne izdelovalne tehnologije za visokokakovostno in trajnostno proizvodnjo
Funder:
ARRS - Slovenian Research Agency
Project number:
P2-0270
Name:
Proizvodni sistemi, laserske tehnologije in spajanje materialov
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