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5150 |
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Wednesday, March 22, 2017, Hall Ford 3:30 PM Additive Manufacturing II |
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Electron beam wire-fed additive manufacture and distortion control |
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Nick Bagshaw / TWI, UK Anita Ward/ TWI, UK Tim Mitchell/ TWI, UK Vitali Jefimovs/ TWI, UK Mike Nunn*/ TWI, UK |
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Wire-feed electron beam additive manufacturing (W-EBAM) has a relatively high deposition rate for additive manufacturing. Similar with any heat input manufacturing process, however, repeated thermal cycles induces plastic strains and corresponding residual stresses in the region of heating, which can result in distortion of the component geometry. The cost of distortion mitigation after processing is an additional factor that needs to be considered during the assessment of the productivity and commercial attractiveness of the process. TWI has extensive knowledge and expertise in distortion control and mitigation in the fabrication of welded structures. Experimental trials and finite element (FE) modelling have been performed at TWI to investigate the potential benefit of applying distortion mitigation methods during processing of W-EBAM components. In this paper the results of the FE modelling and experimental testing of various distortion control methods are presented and discussed Keywords: additive manufacturing, wire-fed, electron beam, W-EBAM, distortion, fabrication, aerospace, FEA modelling. |