Automatic Welding, 2025, №01

2025 №01 (06)

DOI of Article 10.37434/as2025.01.07

2025 №01 (08)

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"Avtomatychne Zvaryuvannya" (Automatic Welding), #1, 2024, pp. 45-49

Movement systems for arc additive manufacturing based on typical equipment

S.M. Minakov¹, A.S. Minakov¹, D.V. Stepanov¹, Ye.P. Chvertko¹, N.M. Strelenko¹, D.M. Vdovychenko², I.M. Vdovychenko²

¹National Technical University of Ukraine «Igor Sikorsky Kyiv Polytechnic Institute». 37 Beresteyskyi Ave., 03056, Kyiv, Ukraine
²E.O. Paton Electric Welding Institute of the NAS of Ukraine 11 Kazymyr Malevych Str., 03150, Kyiv, Ukraine. E-mail: maksimov@paton.kiev.ua

Wire-arc additive manufacturing is becoming widespread in industry due to the high productivity of forming the parts and the ability to build units using traditional welding equipment, such as power sources, wire feeders, gas supply systems, and torches. However, the problems associated with the mandatory need for additional machining of parts produced by arc additive surfacing methods, which, in turn, is caused by residual stresses and deformations in the part and significant surface roughness, remain relevant today. In addition to technological solutions, optimization of part forming processes requires solving a number of problems related to movement of the product and the welding tool during production. In general, such movements need to be performed in a multi-axis coordinate system and with sufficiently high accuracy, while the total movement may be a combined movement of the product and the tool. This paper describes in detail the process of developing multi-axis motion systems for arc additive surfacing units. In contrast to the use of robotic systems as manipulators, the units were built on the basis of universal equipment, which allowed significantly reducing its cost. The parameters required to perform the tasks of arc additive surfacing in shielding gases were achieved as a result of designing equipment that has been successfully tested for additive surfacing of web and flange parts. 6 Ref., 7 Fig.
Keywords: welding, additive manufacturing, wire-arc additive manufacturing, MAG surfacing, unit


Received: 21.10.2024
Received in revised form: 20.12.2024
Accepted: 19.02.2025

References

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2. Knezović, N., Topić, A. (2018) Wire and arc additive manufacturing (WAAM) - a new advance in manufacturing. Lecture Notes in Networks and Systems, 42, 65-71. https://doi.org/10.1007/978-3-319-90893-9_7
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4. Kvasnytskyi, V., Lagodzinskyi, I. (2023) Influence of GMAW and PAW methods of additive arc surfacing and shielding gas composition on surface geometry and metal structure. The Paton Welding J., 11, 21-29. https://doi.org/10.37434/tpwj2023.11.02
5. Yehorov, Y., da Silva, L.J., Scotti, A. (2019) Balancing WAAM production costs and wall surface quality through parameter selection: A case study of an Al-Mg5 alloy multilayernon-oscillated single pass wall. J. of Manufacturing and Materials Processing, 3(2), 32. https://doi.org/10.3390/jmmp3020032
6. Wu, B., Pan, Z., Ding, D. et al. (2018) A review of the wire arc additive manufacturing of metals: Properties, defects and quality improvement. J. of Manufacturing Processes, 35, 127-139. https://doi.org/10.1016/j.jmapro.2018.08.001

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