bead geometry; design of experiment; laser wire-feed metal additive manufacturing; process optimization; Mechanics of Materials; Mechanical Engineering; Industrial and Manufacturing Engineering
Abstract :
[en] Laser wire-feed metal additive manufacturing (LWAM) is an innovative technology that shows many advantages compared with traditional manufacturing approaches. Despite these advantages, its industrial adoption is limited by complex parameter management and inconsistent process quality. To address these issues and improve geometric accuracy, this study explores how process parameters influence bead geometry. We conducted a parameter study varying laser power, wire feed rate, traverse speed, and welding angle. Using a full factorial design with a central composite design methodology, we assessed bead height and width. This allowed us to develop a model to estimate ideal process parameters. The findings offer a detailed analysis of parameter interactions and their effects on bead geometry, aiming to enhance geometric accuracy and process stability in LWAM. Moreover, we have evaluated the proposed process parameters from our developed model, which showed a significant enhancement to the overall quality. This was validated via printing a single layer and multi-layer structures. The quality of the final predicted sample using the proposed method was improved by 40% compared to the best sample produced for the Design of Experiment trials.
Disciplines :
Materials science & engineering
Author, co-author :
ABUABIAH, Mohammad ; University of Luxembourg > Faculty of Science, Technology and Medicine (FSTM) > Department of Engineering (DoE) ; Mechanical and Mechatronics Engineering Department, Faculty of Engineering and Information Technology, An-Najah National University, Palestine
Weidemann, Tizia Charlotte; Fraunhofer Institute for Production Technology IPT, Aachen, Germany
Elahi, Mahdi Amne; Department of Engineering, University of Luxembourg, Luxembourg, Luxembourg
Shaqour, Bahaa ; Mechanical and Mechatronics Engineering Department, Faculty of Engineering and Information Technology, An-Najah National University, Palestine
Day, Robin; Fraunhofer Institute for Production Technology IPT, Aachen, Germany
This research was funded by the BALSAM project, which is part of the EU Framework Programme for Research and Innovation within Horizon Europe\u2014Marie Sklodowska-Curie Postdoctoral Fellowships 2021, under grant agreement No. 101064640.
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