Skip to main content

Prediction of Thermal Conditions of DED With FEA Metal Additive Simulation...

by Lauren E Heinrich, Thomas A Feldhausen, Kyle S Saleeby, Christopher Saldana, Thomas R Kurfess
Publication Type
Conference Paper
Journal Name
Proceedings of the ASME 2021 16th International Manufacturing Science and Engineering Conference
Book Title
ASME 2021 16th International Manufacturing Science and Engineering Conference
Publication Date
Publisher Location
District of Columbia, United States of America
Conference Name
Manufacturing Science and Engineering Conference
Conference Location
Cincinnati, Ohio, United States of America
Conference Sponsor
Conference Date

This paper presents the integration of wire-arc additive manufacturing (WAAM) using Gas Metal Arc Welding (GMAW) into a machine tool to create a retrofit hybrid computer numeric control (CNC) machine tool. GMAW, along with other direct energy deposition systems, has the capacity to deposit material faster than the excess thermal energy can dissipate. This results in the need to allow the part to cool between consecutive layers, which is the most time-consuming part of the additive process. Finite element analysis (FEA) was used in conjunction with monitored build plate surface temperatures during deposition samples to improve adequate dwell time prediction and to develop a cooling system. A deposition was completed where no dwell time was used and the build plate along with the machine table temperatures were monitored. A second deposition was completed where only one bead was deposited and the traverse speed was increased. The GMAW welder was mounted on a 3-axis CNC machine where two square deposition samples were completed. A FEA model was designed and verified using the monitored samples. The model will be used to determine improved depositions speeds and whether forced cooling would allow for an increased deposition rate without structural failure. It was determined the FEA software can be used to accurately model and predict the thermal response of WAAM AM components.