Breakthrough in WAAM
The UK Research Consortium ‘ HPWAAM ’ ( High Productivity Wire Arc Additive Manufacturing group ) funded by Innovate UK – the UK ’ s Innovation Agency ; grant number 53610 – and led by Weir Group , has exceeded key research milestones , accelerating additive manufacturing technologies beyond previous levels in terms of deposition rates and scale . Productivity and efficiency performance achieved will help to accelerate the adoption of additive manufacturing in high-volume steel industries such as construction and mining .
The collaborative project between Weir Group ; BOC , a Linde company ; WAAM3D ; Foster + Partners ; Steelo ; Wintwire and Cranfield University is on track to deliver its objectives by the end of 2023 . It has exceeded key interim project objectives such as increasing steel deposition rates to 15kg / h , from a baseline of 3kg / h , using a novel Wire Arc Additive Manufacturing ( WAAM ) process . It has also applied new adaptive toolpath programming for different layer heights , unlocking potential for greater scales and complexities . The group has also successfully demonstrated the manufacturing of a 150kg part using high-deposition rate and in-process cryogenic cooling .
The reported progress means that the consortium can now seek to industrialise HPWAAM for large-scale engineering components , featuring full thermal control and variable resolution . The project is scheduled to complete by the end of 2023 and brings together seven specialist organisations who are backed by £ 1.2m of funding from Innovate UK . The technology presents substantial potential sustainability improvements such as reducing greenhouse gas emissions compared to traditionally energy-intensive manufacturing processes .
Looking ahead , the project ’ s endusers will create updated Design for Additive Manufacturing frameworks that will transform a series of existing commercial components in the latter phase of the HPWAAM programme .
The HPWAAM project will take the WAAM process to the next level of industrialisation . The main objective is to increase the productivity of the WAAM process and further reduce part building time and costs . Build strategies and approaches will be improved to achieve a higher level of resolution in WAAM components , without compromising integrity and productivity .
drawings to final structures using WAAM , two individual pieces have been integrated into a single part , lead times have been reduced and the component has used 30 times less raw material than if it was created via traditional processes . By using the WAAM process , more than 200kg of Ti-6Al-4V has been saved for each item .
As more and more companies begin to
FOCUS ON ADDITIVE MANUFACTURING
WAAM3D technology for the HPWAAM project .
By using the WAAM process , more than 200kg of Ti-6Al-4V has been saved for each item
explore ways to improve the manufacturing efficiency of their medium-to-large scale engineering components , it is no wonder that WAAM is taking off in aerospace design . The potential benefits that WAAM technology can offer the aerospace components industry have only just begun to be explored . n
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About WAAM3D
WAAM3D provides a total , turnkey solution delivered via a WAAM ecosystem that is based on in-house developed hardware , software , services and materials . It has won several awards including the 2022 ‘ TCT Award for Best Hardware ’ in the non-polymer category for its RoboWAAM system . WAAM3D was also recognised as one of the ten most innovative 3D-printing companies of 2022 by All3DP magazine for the digital maker .
It has experience of creating components using large-scale metal additive manufacturing for the aerospace , energy , marine and mining industries .
By pushing the boundaries of WAAM capabilities , the company aims to help those in aerospace , oil and gas , mining and other industrial applications to increase design freedom , reduce costs and shorten the lead times of a range of medium-to-large sized components .
It also supports various UK Catapult centres and other research bodies that are working on the latest innovations in manufacturing .
ISMR July / August 2023 | ismr . net | 21