*WINNER* Reducing Post-Processing and Allowing Free Complexity in Metal Additive Manufacturing

Abstract

This won best undergraduate poster in Manufacturing and Engineering Technology.

Wire arc additive manufacturing (WAAM) is a promising additive manufacturing (AM) technology for small and medium sized companies. However, only large companies can use it because of the time and cost intensive post-processing. Usually a wire electrical discharge machine (wire EDM) is used to detach the part from the substrate because of the ability to cut through thick material. This is a machine many small enterprises cannot afford. In addition, the EDM removal procedure is limited to flat bottom geometries. When using the EDM removal, another process is needed to give the bottom a complex geometry; extra processing (writing G-codes, grinding, and cleaning) is necessary. This defeats the purpose of additive manufacturing and discourages enterprises from using it. Our proposed AM method allows a free geometry complexity.  EDM detaching is the main deterrent companies have against WAAM. To remove this encumbrance, we are researching the application of different ceramic coatings between the AM part and the substrate – aluminum oxide, yttrium oxide, zirconium oxide, boron nitride, etc. – as well as cooling methods to facilitate cold welds. Success is determined by the ability to remove the part from the substrate with a tool any company large or small has: a hammer.  This project’s main goal is to increase feasibility of WAAM in manufacturing by shortening lead time, a problem common in AM due to post processing, with the ability to build complex bottom geometries by characterizing relationships between welding materials, ceramics, cooling methods, and process parameters.