The presented book deals with the use of Wire Arc Additive Manufacturing (WAAM) as a means of stiffening and reinforcing free-form sheet metal as an application in facade. The main focus of the research is developing a methodology for welding ontop of pre-bent sheet metal; including digitizing of arbitrarily-formed sheet metal, developing of process-parameters for welding on thin sheet metal and generating force-responsive welding paths.
The research is focused on singly-curved sheet metal profiles, and is concluded by the production of a number of small-scale prototypes which illustrate the potentials for reinforcing sheet metal using WAAM.
Author(s): Christopher Borg Costanzi
Series: Mechanik, Werkstoffe und Konstruktion im Bauwesen, 68
Publisher: Springer Vieweg
Year: 2023
Language: English
Pages: 206
City: Wiesbaden
Zusammenfassung
Abstract (EN)
Preface
Table of Contents
PART 1
1 Introduction
1.1 Wire Arc Additive Manufacturing and Mass Customization
1.2 WAAM and complex-geometry facades
1.3 Research Framework
1.4 Motivation
1.5 Research Questions
1.6 Structure
2 Sheet metal as a material
2.1 Production of Sheet Metal
2.1.1 From raw material to a blank billet
2.2 Shaping into thin sheet material
2.3 Sheet metal facades
2.3.1 Standing Seam and Snap-lock Cladding
2.3.2 Shingle and Flat-lock facades
2.3.3 Cassettes
2.3.4 Alucobond Facades
2.3.5 Custom Systems
2.4 Sheet Metal forming Techniques
2.4.1 Hammering
2.4.2 Sheet bending.
2.4.3 Sheet Spinning
2.4.4 Deep drawing
2.4.5 Stretch Forming
2.4.6 Multiple Point Forming (MPF)
2.4.7 Hydro Forming
2.4.8 Incremental Sheet Forming (ISF)
2.4.9 Bead Rolling
3 Additive Manufacturing
3.1 Additive Manufacturing Processes
3.1.1 Material Extrusion (ME)
3.1.2 Vat Polymerization (VP)
3.1.3 Material Jetting (MJ) and Binder Jetting (BJ)
3.1.4 Powder Bed Fusion (PBF)
3.1.5 Directed Energy Deposition (DED)
3.1.6 Laminated Object Manufacturing (LOM)
3.1.7 Discussion
3.2 Additive Manufacturing of Metals
3.2.1 Powder Bed Fusion
3.2.2 Powder-Directed Energy Deposition (P-DED)
3.2.3 Wire-Directed Energy Deposition (W-DED)
3.2.4 Discussion
4 Wire Arc Additive Manufacturing
4.1 WAAM in Construction
4.2 WAAM Process
4.3 Heat Transfer Mechanisms
4.4 Cold Metal Transfer (CMT) Welding
4.5 Process Parameters
4.5.1 Shielding gas
4.5.2 Contact-tube-weld-distance (CTWD)
4.5.3 Travelling Speed (Ts)
4.5.4 Wire feed speed (Wfs)
4.5.5 Combination of parameters
5 Welding distortion in thin plates
5.1 Discussion
5.2 Mitigation Strategies
5.2.1 Flame Straightening
5.2.2 Mechanical Tensioning
5.2.3 Thermal Tensioning
5.2.4 Low Stress Non-Distortion (LSND) Welding
5.2.5 Dynamically-Controlled Low Stress Non-Distortion (DC-LDNS Welding
5.3 Discussion
PART 2
6 Proposed Hybrid WAAM and Thin Sheet Metal Welding
6.1 Scanning
6.1.1 Photogrammetry
6.1.2 3D Laser Scanning
6.1.3 Structured Light Scanning (Microsoft Kinect)
6.1.4 Tactile Sensing
6.2 Process Parameter Studies
6.2.1 Pre-Investigation
6.2.2 Parameters on sheet metal thin sheet material
6.2.3 Discussion
6.3 Material Testing
6.3.1 Welded sheet Tensile Testing
6.3.2 4 Point Bending Test
6.4 Formulating Welding Strategies
6.4.1 Topology Optimization
6.4.2 Proposing a curve-based approach
6.5 Preparing print paths
6.5.1 Robotic slicing
6.5.2 Polynomial Regression and Parametric robotic programming
6.6 Detailing
7 Discussion
PART 3
8 Summary and Future Outlook
References
