View
254
Download
3
Category
Preview:
Citation preview
COST CRM-EXTREME, 16.6.2017, Prague, Czech Republic
ROBOTIC WIRE ARC ADDITIVE MANUFACTURING OF METAL PRODUCTS
Damjan Klobčar1, Janez Tušek1, Maja Lindič 1, Boris Bell 2
1 Faculty of Mechanical Engineering, University of Ljubljana, Aškerčeva 6, 1000 Ljubljana, Slovenia;
e-mail: damjan.klobcar@fs.uni-lj.si2 School center Postojna, Cesta v Staro vas 2, 6230 Postojna, Slovenia
University of LjubljanaFakulteta za strojništvoLaboratorij za varjenje
D. Klobčar et al. Robotic WAAM of metal products COST CRM-EXTREME, 16.6.2017, Prague, Czech Republic
University of LjubljanaFaculty of Mechanical
EngineeringWelding Laboratory
INTRODUCTION
D. Klobčar et al. Robotic WAAM of metal products COST CRM-EXTREME, 16.6.2017, Prague, Czech Republic
University of LjubljanaFaculty of Mechanical
EngineeringWelding Laboratory
AM technologies
D. Klobčar et al. Robotic WAAM of metal products COST CRM-EXTREME, 16.6.2017, Prague, Czech Republic
University of LjubljanaFaculty of Mechanical
EngineeringWelding Laboratory
Comparison of different AM technologies
D. Klobčar et al. Robotic WAAM of metal products COST CRM-EXTREME, 16.6.2017, Prague, Czech Republic
University of LjubljanaFaculty of Mechanical
EngineeringWelding Laboratory
Advantages and disadvantages of AM technologies
10
10
10
10
1010
10
10
10
Build rate
Complexity
Accuracy
Cost savings
Material utilisationMech. properties
Post-processing requirement
Platform flexibility
Part size
Powder-bed
Blown-powder
WAAM
Hi. Dep. Wire-fed
D. Klobčar et al. Robotic WAAM of metal products COST CRM-EXTREME, 16.6.2017, Prague, Czech Republic
University of LjubljanaFaculty of Mechanical
EngineeringWelding Laboratory
History of WAAM
• 1926 Baker – patent of electric arc as heat source for deposition of melted material to manufacture 3D object
• 1971 Ujiie (Mitsubishi) – manufacturing of pressure valve with SAW, ESW and TIG welding – multi wire and multi materials.
• 1983 Kussmaul – shape welding of large and high quality nuclear construction parts from 20MnMoNi5 steel (build rate 80 kg/h, mass 79 ton).
• 1993 Prinz, Weiss – patent of hybrid CNC machine for welding and milling – „Shape Deposition Manufacturing“
• 1994-1999 Cranfield University – development of „Shape Metal Deposition“ process for manufacturing of castings for aircraft engines for Rolls Royce.
• H2020–FoF-2016- 723917-OPENHYBRID from CAD to production with advanced all-in-one machineshttp://www.ewf.be/news/openhybrid-kom.aspx .
D. Klobčar et al. Robotic WAAM of metal products COST CRM-EXTREME, 16.6.2017, Prague, Czech Republic
University of LjubljanaFaculty of Mechanical
EngineeringWelding Laboratory
Materials and products
Titaniumalloys
Aluminumalloys
Tool steel Other alloys Stainless steel Temperature resistant
Ti-6Al-4V Al-Si-Mg H13 IN625 316 & 316L MoRe
ELI Ti 6061 IN718 420 Ta-W
CP Ti 347 CoCr
γ-TiAl PH 17-4
Usually used material for Additive Manufacturing
0.8 metre tall aluminium/steelconics built for Lockheed Martin
2.5 metre x 1.2 metre aluminium wing
rib for Bombardier
1 metre tallturbine blade (steel)
Projectiles
Dissimilar part Steel/bronze (CuSi3%)
D. Klobčar et al. Robotic WAAM of metal products COST CRM-EXTREME, 16.6.2017, Prague, Czech Republic
University of LjubljanaFaculty of Mechanical
EngineeringWelding Laboratory
Samples from our laboratory
D. Klobčar et al. Robotic WAAM of metal products COST CRM-EXTREME, 16.6.2017, Prague, Czech Republic
University of LjubljanaFaculty of Mechanical
EngineeringWelding Laboratory
Materials – Steel, Titanium, Aluminium
Mass[kg]
BTF Cost [k₤]
Costred.
SteelOriginal, machined 36 12 1.6 -
Original, WAAM 36 2.3 0.7 55%
TitaniumOriginal, machined 20 12 16.2 -
Original, WAAM 20 2.3 5 69%
Aircraft landing gear
Design options (MRR =[323 kg/h])
BTF Cost [k₤]
Costred.
Machined from solid 45 4.4 -
WAAM, option 1 2.9 1.7 61%
WAAM, option 2 12.3 1.9 56%
Buy – to – Fly = efficiency of fedstock material= Vfeedstock/ Vproduct
Aircraft wing structure
D. Klobčar et al. Robotic WAAM of metal products COST CRM-EXTREME, 16.6.2017, Prague, Czech Republic
University of LjubljanaFaculty of Mechanical
EngineeringWelding Laboratory
EXPERIMENTAL PART
D. Klobčar, … 3D tiskanje kovinskih…. DVT in DNVT 2016, IZV, Ljubljana, Slovenija, 2.11.2016
Determination of parameters for stable WAAM process – thin walls
• Welding power source: FroniusTransPuls Synergic 3200 CMT R
• Welding robot: ABB IRB 140-6/0.8
• Temperature measurement: VOLTCRAFT M – 3850
• Base metal: S335 dimension: 100x25x8 mm
• Filler wire: G3Si1 (VAC 60)• Shielding gas: CO2, CORGON 18,
Ar • Gas flow: 10 l/min
• Parametric analysis (I = 40, 90, 140 A, wspeed = 3, 7.5, 12 mm/s) – standard,
CMT and pulse welding control,
• Welding in positions:
PA, PC and PG
•Analysis (tensile test, hardness measurement, metallographic analysis).
• Manufacturing of final part (CAD + SprutCAM – path programing).
D. Klobčar et al. Robotic WAAM of metal products COST CRM-EXTREME, 16.6.2017, Prague, Czech Republic
University of LjubljanaFaculty of Mechanical
EngineeringWelding Laboratory
RESULTS
STANDARD PULS CMT
Optimization of welding parameters
D. Klobčar et al. Robotic WAAM of metal products COST CRM-EXTREME, 16.6.2017, Prague, Czech Republic
University of LjubljanaFaculty of Mechanical
EngineeringWelding Laboratory
Wavy surface
Process optimization
• Eliminate wavy surface with optimization of heat input
Alternating directionSlope - Welding to one side
(I=90 A , v=7,5 mm/s)
0
5
10
15
20
25
0 20 40 60 80 100 120 140 160
Vo
ltag
e-
U [
V]
Welding current - I [A]
CMT
CMT+PULZ
1. Optimisaiton 2. Optimisation
• Eliminate the slope with alternately changing welding direction and control of interpass temperature
D. Klobčar et al. Robotic WAAM of metal products COST CRM-EXTREME, 16.6.2017, Prague, Czech Republic
University of LjubljanaFaculty of Mechanical
EngineeringWelding Laboratory
Optimization of process parameters -CMT+PULS
I=59 A, v=5 mm/s, Q=103,8 kJ/m I=141 A, v=7,5 mm/s, Q=419,2 kJ/mI=90 A, v=7,5 mm/s, Q=244,8 kJ/m
0,5
1
1,5
2
2,5
3
2 3 4 5 6 7 8 9 10 11 12 13
Laye
rh
eigh
t[m
m]
Welding speed [mm/s]
I = 40 A (hladno varjen)
I = 40 A ( povp. navarjene stene -medvarkovna tem. 200 °C)
1
2
3
4
5
2 3 4 5 6 7 8 9 10 11 12 13La
yer
wid
th[m
m]
Welding speed [mm/s]
40 A (cold welding)
40 A (average interpass
temperature 200 °C)
D. Klobčar et al. Robotic WAAM of metal products COST CRM-EXTREME, 16.6.2017, Prague, Czech Republic
University of LjubljanaFaculty of Mechanical
EngineeringWelding Laboratory a) I = 40 A, v = 5 mm/s
b) I = 90 A, v = 7,5 mm/sc) I = 140 A, v = 7,5 mm/s
Higher energy input -> wider and higher weld deposit.
a) b) c)PA
I = 40 A, v = 5 mm/s
Lower energy input -> preventing of excessive melting.
I = 90 A, v = 7,5 mm/s
Lower energy input -> holding the melt at end of weld.
PG
PC
Successful welding in different welding positions
D. Klobčar et al. Robotic WAAM of metal products COST CRM-EXTREME, 16.6.2017, Prague, Czech Republic
University of LjubljanaFaculty of Mechanical
EngineeringWelding Laboratory
Tensile strength of deposit is lower than the filler metal
0
0,2
0,4
0,6
0,8
1
1,2
0 2 4 6
Forc
e[k
N]
Elongation [mm]
0
0,2
0,4
0,6
0,8
1
1,2
0 1 2 3 4 5
Forc
e[k
N]
Elongation [mm]
0
0,2
0,4
0,6
0,8
1
1,2
1,4
0 1 2 3 4
Forc
e[k
N]
Elongation [mm]
a)
b)
c)
45° Angle
90° Angle
0° Angle
An
gle
[°]
The filler metal: Rm = 500 – 640 MPa
D. Klobčar et al. Robotic WAAM of metal products COST CRM-EXTREME, 16.6.2017, Prague, Czech Republic
University of LjubljanaFaculty of Mechanical
EngineeringWelding Laboratory
WAAM of tube welded at I = 59 A, v = 5 mm/s
D. Klobčar et al. Robotic WAAM of metal products COST CRM-EXTREME, 16.6.2017, Prague, Czech Republic
University of LjubljanaFaculty of Mechanical
EngineeringWelding Laboratory
How to affect the
use of CRM
Potential use of the technology
- To produce the tools with increased lifetime.
- Multimaterialcomponents
D. Klobčar et al. Robotic WAAM of metal products COST CRM-EXTREME, 16.6.2017, Prague, Czech Republic
University of LjubljanaFaculty of Mechanical
EngineeringWelding Laboratory
Project proposalThe use of additive manufacturing to increase
the lifetime of industrial tooling
D. Klobčar et al. Robotic WAAM of metal products COST CRM-EXTREME, 16.6.2017, Prague, Czech Republic
University of LjubljanaFaculty of Mechanical
EngineeringWelding Laboratory
CONCLUSIONS
A parametric analysis of WAAM using MIG/MAG welding for production of thin wall structures was done.
• An optimally low heat input during weld deposition (100-300 kJ/m) must be done in order to make stable deposition of layer dimensions. At < 100 kJ/m wavy weld deposition; at > 300 kJ/m melting of material.
• It is important to control the weld interpass temperature. It should not exceed 100 °C.
• An optimal process to control was achieved by combination of CMT and pulsed welding.
• Welding in different welding position is possible; the easiest welding is done in PA position. When welding in other positions we must consider the gravity, weld interpass temperature, and energy input.
D. Klobčar et al. Robotic WAAM of metal products COST CRM-EXTREME, 16.6.2017, Prague, Czech Republic
University of LjubljanaFaculty of Mechanical
EngineeringWelding Laboratory THANK YOU FOR ATTENTION
We are open for collaboration (damjan.klobcar@fs.uni-lj.si)
Acknowledgment
The work was partly sponsored by EU European Regional Development Fund and Ministry of Education,
Science and Sport of the Republic of Slovenia under the Strategy of Smart Specialisation Project MARTINA
(MAteRials and TehnologIes for New Aplications) http://www.martina-eu.net/si/ .
The work was partly sponsored by EU European Social Found, Ministry of Education, Science and Sport of the
Republic of Slovenia and Slovene human resources development and scholarship fund under the project name
„Robotic weld surfacing“.
D. Klobčar et al. Robotic WAAM of metal products COST CRM-EXTREME, 16.6.2017, Prague, Czech Republic
University of LjubljanaFaculty of Mechanical
EngineeringWelding Laboratory
Recommended