Additive Manufacturing (AM) has become widely adopted in various industries with Laser AM being the most popular technology for metallic materials. Laser-wire DED (Directed Energy Deposition) is becoming an interesting additive manufacturing method for building large freeform structures that are not constrained by the printing machine dimensions. However, the WAAM process (Wire Arc Additive Manufacturing) is currently more widely used with several high-profile applications, such as bridges, pressure vessels, tanks, and barrels, due to its basic origins in MIG welding. The opportunities for these wire-DED process variants are immense in terms of reduced manufacturing complexity, costs, lead times, and tooling requirements, with more design flexibility. This conference paper discusses feature development testing for 3D printing 30in diameter compressor casings, comparing the advantages and disadvantages between the wire-arc and wire-laser process variants of wire-DED. Using aluminum 5XXX series alloy wire, demonstration test pieces were produced with features including stiffening ribs and local reinforcements. The quality of the printed development test pieces was assessed by radiographic inspections, metallurgical assessments, and dimensional scans. Further demonstrations could include split casings, ports, lugs, and other features that can be integrated as one single part instead of many, simplifying the supply chain with potentially significant gains in productivity.
Keywords
- Additive Manufacturing
- Aluminum Alloy
- Wire-Arc Am
- Wire-Ded
- Wire-Laser Am