Titel Deelnemers "Evaluating shielding gas-filler wire interaction in bi-metallic wire arc additive manufacturing (WAAM) of creep resistant steel-stainless steel for improved process stability and build quality" "Fereidoon Marefat, Angshuman Kapil, Seyed Aref Banaee, Patrick Van Rymenant, Abhay Sharma" "Numerical prediction of microstructure and hardness for low carbon steel wire Arc additive manufacturing components" "Yong Ling, Junyan Ni, Joachim Antonissen, Haithem Ben Hamouda, John Vande Voorde, Magd Abdel Wahab" "The objective of this research is to define an optimized strategy for wire arc additive manufacturing (WAAM) process with a numerical tool. In this paper, a three-dimensional scaled steel plate model (120 mm x 24 mm x 6 mm) is built for numerical simulations to replace the expensive physical WAAM experiments. A series of thermo-metallo-mechanical analyses is conducted by using ABAQUS CAE user subroutines in which, thermal, metallurgical and mechanical models for gas metal arc welding (GMAW) process are implemented. Groups of variables in WAAM process namely wire melting current, voltage and torch moving speeds, as well as interval layer cooling coefficients, are chosen as input parameters of the artificial neural network (ANN). The two targeted values are hardness and ultimate strength of the steel plate model, which are obtained by fully coupled thermo-metallo-mechanical simulations or by quick results from commercial software JmatPro, and by real measurements on the test samples of WAAM experimental plates. In this primary study, Taguchi algorithm is used for data preparations of the numerical experiments. The tests are fulfilled with Neural Networks (NN) tool in MATLAB. A typical three-layer feedforward network is used for general works. The developed models show good prediction capability for hardness and ultimate strength. The ANN algorithm presents high potential in bidirectional modeling to develop the WAAM strategy tool. It is possible to realize the inverse modeling from properties obtained by fractions of phase volume to WAAM processing parameters." "A benchmark of mechanical properties and operational parameters of different steel filler metals for wire arc additive manufacturing" "Rafael Nunes, Nelis Vandermeiren, Wim Verlinde, Dibakor Boruah, Robin Motte, Wim De Waele" "Additive manufacturing processes play a disruptive role in several industrial sectors. Among them, wire arc additive manufacturing (WAAM) is a very promising process for the production of large-scale steel components and structures. As a common characteristic of innovative technologies, this process requires additional research and experimental work in order to understand how its thermal cycles will modify the mechanical and metallurgical properties of the manufactured components. Considering the lack of literature on the properties of WAAM components from specific steel alloys, the present work proposes a benchmark evaluation of five different steel filler metals based on their mechanical properties and operational parameters when applied for additive manufacturing. The mechanical properties, such as the tensile strength, yield strength, elongation, Charpy impact toughness, and hardness, were evaluated together with operational parameters such as cost, printability, spatter, and fume formation during manufacturing, defect-free printing, and heat input. These were analyzed in order to obtain a full evaluation and comparison of the five filler metals. The experimentally determined results of every above-mentioned aspect were higher or similar to the values found in the literature for generic steel filler metals used in additive manufacturing. This means that a designer or welding engineer can select the WAAM steel filler metal for further testing based on the welding wire datasheet. Besides that, a comparison was performed between blocks manufactured by WAAM with some frequently used base metals, in plate format, confirming its applicability." "Development of low-cost production process for prototype components based on Wire and Arc Additive Manufacturing (WAAM)" "Nataliia Chernovol, Bert Lauwers, Patrick Van Rymenant" "Wire and Arc Additive Manufacturing is a fast-growing technology that allows to produce medium to large metal parts in both a material- and cost-efficient way. Because it is based on existing welding technology, it is certainly an affordable technology for small and medium sized companies. However, the integration of this technology for prototype manufacturing still needs certain difficulties to be solved, such as the determination of process parameters and deposition strategies, programming software to be used, postprocessing, etc. This paper focuses on the different steps to be taken to adapt the existing Gas Metal Arc Welding (GMAW) technology into an affordable and efficient WAAM technology. The technology developed has been integrated within a robotized platform. Experiments for the determination of bead geometry were conducted both for conventional GMAW (MAG welding) and Cold Metal Transfer (CMT) welding. A central composite rotatable design (CCD) was used for fitting second-order response surfaces, allowing to predict bead geometry corresponding to the welding parameters and to set the required information for generating the robot programs. Also, productivity of both processes was compared, highlighting significant dependency on part’s geometry and dimensions as also the quantity of parts simultaneously produced." "Design Strategies for Bi-Metallic Additive Manufacturing in the Context of Wire and Arc Directed Energy Deposition" "Fereidoon Marefat, Angshuman Kapil, Nataliia Chernovol, Patrick Van Rymenant, Abhay Sharma" "While the recent research in manufacturing bi-metallic structures using wire and arc directed energy deposition focuses on feasibility studies to understand material compatibility, the study presented here encircles a larger design framework, integrating deposition process, intermediate surface conditions, and mutual deposition (hatching) direction. The investigation addresses the issues associated with manufacturing actual bi-metallic structures and shades light on the intrinsic mechanism responsible for process-induced anisotropy and resulting interfacial strength. Interfacial shear tests of the candidate bi-metallic pair of low-carbon steel-316L stainless steel reveal that the intermediate machining before deposition of the second material, if deposited with low dilution and low heat input has a limited effect on the final build quality. The deposition direction influences the isotropy, i.e., strength improves when the shear force acts transversely to the deposition direction of the second material. Interlocking promoted by favorable deposition direction, as revealed by fractography, combined with metallurgical bonding, enhances the interfacial strength. Despite element migration and hardness spike in the interface up to 500 HV due to martensitic needles, a defect-free bi-metallic structure was possible with shear strengths over 400 MPa. The investigation contributes to the fundamental understanding of the approaches suitable for the deposition of sound bi-metallic structures." "Challenges in assessing the sustainability of wire + arc additive manufacturing for large structures" "Anne C.M. Bekker, Jouke Casper Verlinden, Giorgia Galimberti" "Generalised overlapping model for multi-material wire arc additive manufacturing (WAAM)" "Seyed Aref Banaee, Angshuman Kapil, Abhay Sharma" "Active and Passive Thermal Management in Wire Arc Additive Manufacturing" "Abhay Sharma" "Life cycle assessment of wire plus arc additive manufacturing compared to green sand casting and CNC milling in stainless steel" "Anne C.M. Bekker, Jouke Casper Verlinden" "Digital image correlation for measuring full-field residual stresses in wire and arc additive manufactured components" "Dibakor Boruah, Nele Dewagtere, Bilal Ahmad, Rafael Nunes, Jeroen Tacq, Xiang Zhang, Hua Guo, Wim Verlinde, Wim De Waele"