Invention Reference Number
Wire arc additive manufacturing has limited productivity and casting processes require complex molds that are expensive and time-consuming to produce. This technology combines the benefits of wire-arc AM processes – the creation of complex geometric shapes layer by layer without forms or molds, with the electroslag casting process – which has extremely high deposition rates. The invention produces large near net shape casting equivalents with optimized geometry and microstructural properties.
Description
This technology is a hybrid process for creating infrastructure-scale near net shape components via additive manufacturing (AM). It combines the resolution of wire-arc AM processes and the deposition rates of electroslag casting processes to produce metallic components higher rates and with lower lead times than wire-arc AM or conventional castings alone, with the potential to produce better mechanical properties then either of the techniques individually through topology and microstructural optimization.
Benefits
- Increase productivity
- Less expensive
- Higher deposition rates
- Potentially improved material properties
- No complex molds or forms required
- Can produce optimized multi-material components
- Domestic production
- Reduce lead times for large metallic components
- Reduced infrastructure compared to conventional foundries
- Reduced labor requirements compared to conventional foundries
- Eliminates multi-step casting and welding of assemblies for complex metallic structures
Applications and Industries
- Large casting producers
- Hydropower runners
- Pressure vessels
- Defense castings
- Clean energy castings, i.e. wind turbines, bed plates
- Gas infrastructure, deep water drilling components
- Optimized structures, i.e. architectural features, trusses, beams, etc.
Contact
To learn more about this technology, email partnerships@ornl.gov or call 865-574-1051.
