Wire arc additive manufacturing of a high-strength low-alloy steel part

Detalhes bibliográficos
Autor(a) principal: Kokare, Samruddha
Data de Publicação: 2024
Outros Autores: Shen, Jiajia, Fonseca, Pedro P., Lopes, João G., Machado, Carla M., Santos, Telmo G., Oliveira, João P., Godina, Radu
Tipo de documento: Artigo
Idioma: eng
Título da fonte: Repositório Científico de Acesso Aberto de Portugal (Repositórios Cientìficos)
Texto Completo: http://hdl.handle.net/10362/173277
Resumo: Funding Information: Samruddha Kokare acknowledges Funda\u00E7\u00E3o para a Ci\u00EAncia e a Tecnologia (FCT\u2013MCTES) for its financial support via the MIT-Portugal Program PhD grant PRT/BD/154651/2023. Jiajia Shen acknowledges the China Scholarship Council for funding the Ph.D. grant CSC No. 201808320394. Pedro Fonseca acknowledges FCT\u2013MCTES for funding the PhD grant 2022.13883.BD. J.G. Lopes acknowledges FCT\u2013MCTES for its financial support via the Ph.D. grant 2020.07350.BD. J. P. Oliveira acknowledges funding by national funds from FCT\u2013Funda\u00E7\u00E3o para a Ci\u00EAncia e a Tecnologia, I.P., in the scope of the projects LA/P/0037/2020, UIDP/50025/2020, and UIDB/50025/2020 of the Associate Laboratory Institute of Nanostructures, Nanomodelling and Nanofabrication\u2013i3N. Samruddha Kokare, Radu Godina, Telmo G. Santos, and Carla M. Machado acknowledge Funda\u00E7\u00E3o para a Ci\u00EAncia e a Tecnologia (FCT\u2013MCTES) for its financial support for its financial support via the project UIDP/00667/2020 and UIDB/00667/2020 (UNIDEMI). This activity has received funding from the European Institute of Innovation and Technology (EIT)\u2013Project Smart WAAM: Microstructural Engineering and Integrated Non-Destructive Testing. This body of the European Union receives support from the European Union\u2019s Horizon 2020 research and innovation programme. Funding Information: Open access funding provided by FCT|FCCN (b-on). Samruddha Kokare acknowledges Funda\u00E7\u00E3o para a Ci\u00EAncia e a Tecnologia (Portugal) for its financial support via the MIT-Portugal Program PhD grant PRT/BD/154651/2023. Jiajia Shen acknowledges the China Scholarship Council for funding the Ph.D. grant CSC No. 201808320394. Pedro Fonseca acknowledges FCT\u2013MCTES for funding the PhD grant 2022.13883.BD. J.G. Lopes acknowledges FCT\u2013MCTES for its financial support via the Ph.D. grant 2020.07350.BD. J. P. Oliveira acknowledges funding by national funds from FCT\u2013Funda\u00E7\u00E3o para a Ci\u00EAncia e a Tecnologia, I.P., in the scope of the projects LA/P/0037/2020, UIDP/50025/2020, and UIDB/50025/2020 of the Associate Laboratory Institute of Nanostructures, Nanomodelling and Nanofabrication\u2013i3N. Samruddha Kokare, Radu Godina, Telmo G. Santos, and Carla M. Machado acknowledge Funda\u00E7\u00E3o para a Ci\u00EAncia e a Tecnologia (FCT-MCTES) for its financial support for its financial support via the project UIDP/00667/2020 and UIDB/00667/2020 (UNIDEMI). This activity has received funding from the European Institute of Innovation and Technology (EIT)\u2013Project Smart WAAM: Microstructural Engineering and Integrated Non-Destructive Testing. This body of the European Union receives support from the European Union\u2019s Horizon 2020 research and innovation programme. Publisher Copyright: © The Author(s) 2024.
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spelling Wire arc additive manufacturing of a high-strength low-alloy steel partenvironmental impacts, costs, and mechanical propertiesCNC machiningLaser powder bed fusionLife cycle assessmentLife cycle costingMechanical characterizationWire arc additive manufacturingControl and Systems EngineeringSoftwareMechanical EngineeringComputer Science ApplicationsIndustrial and Manufacturing EngineeringSDG 7 - Affordable and Clean EnergySDG 12 - Responsible Consumption and ProductionFunding Information: Samruddha Kokare acknowledges Funda\u00E7\u00E3o para a Ci\u00EAncia e a Tecnologia (FCT\u2013MCTES) for its financial support via the MIT-Portugal Program PhD grant PRT/BD/154651/2023. Jiajia Shen acknowledges the China Scholarship Council for funding the Ph.D. grant CSC No. 201808320394. Pedro Fonseca acknowledges FCT\u2013MCTES for funding the PhD grant 2022.13883.BD. J.G. Lopes acknowledges FCT\u2013MCTES for its financial support via the Ph.D. grant 2020.07350.BD. J. P. Oliveira acknowledges funding by national funds from FCT\u2013Funda\u00E7\u00E3o para a Ci\u00EAncia e a Tecnologia, I.P., in the scope of the projects LA/P/0037/2020, UIDP/50025/2020, and UIDB/50025/2020 of the Associate Laboratory Institute of Nanostructures, Nanomodelling and Nanofabrication\u2013i3N. Samruddha Kokare, Radu Godina, Telmo G. Santos, and Carla M. Machado acknowledge Funda\u00E7\u00E3o para a Ci\u00EAncia e a Tecnologia (FCT\u2013MCTES) for its financial support for its financial support via the project UIDP/00667/2020 and UIDB/00667/2020 (UNIDEMI). This activity has received funding from the European Institute of Innovation and Technology (EIT)\u2013Project Smart WAAM: Microstructural Engineering and Integrated Non-Destructive Testing. This body of the European Union receives support from the European Union\u2019s Horizon 2020 research and innovation programme. Funding Information: Open access funding provided by FCT|FCCN (b-on). Samruddha Kokare acknowledges Funda\u00E7\u00E3o para a Ci\u00EAncia e a Tecnologia (Portugal) for its financial support via the MIT-Portugal Program PhD grant PRT/BD/154651/2023. Jiajia Shen acknowledges the China Scholarship Council for funding the Ph.D. grant CSC No. 201808320394. Pedro Fonseca acknowledges FCT\u2013MCTES for funding the PhD grant 2022.13883.BD. J.G. Lopes acknowledges FCT\u2013MCTES for its financial support via the Ph.D. grant 2020.07350.BD. J. P. Oliveira acknowledges funding by national funds from FCT\u2013Funda\u00E7\u00E3o para a Ci\u00EAncia e a Tecnologia, I.P., in the scope of the projects LA/P/0037/2020, UIDP/50025/2020, and UIDB/50025/2020 of the Associate Laboratory Institute of Nanostructures, Nanomodelling and Nanofabrication\u2013i3N. Samruddha Kokare, Radu Godina, Telmo G. Santos, and Carla M. Machado acknowledge Funda\u00E7\u00E3o para a Ci\u00EAncia e a Tecnologia (FCT-MCTES) for its financial support for its financial support via the project UIDP/00667/2020 and UIDB/00667/2020 (UNIDEMI). This activity has received funding from the European Institute of Innovation and Technology (EIT)\u2013Project Smart WAAM: Microstructural Engineering and Integrated Non-Destructive Testing. This body of the European Union receives support from the European Union\u2019s Horizon 2020 research and innovation programme. Publisher Copyright: © The Author(s) 2024.Additive manufacturing (AM) technologies have demonstrated a promising material efficiency potential in comparison to traditional material removal processes. A new directed energy deposition (DED) category AM process called wire arc additive manufacturing (WAAM) is evolving due to its benefits which include faster build rates, capacity to build large volumes, and inexpensive feedstock materials and machine tools compared to more technologically mature powder-based AM technologies. However, WAAM products present challenges like poor surface finish and lower dimensional accuracy compared to powder-based processes or machined parts, prevalence of thermal distortions, residual stresses, and defects like porosity, cracks, and humping, often requiring post-processing operations like finish machining and heat treatment. These post-processing operations add to the production cost and environmental footprint of WAAM-built parts. Therefore, considering the opportunities and challenges presented by WAAM, this paper analyses the environmental impact, production costs, and mechanical properties of WAAM parts and compares them with those achieved by laser powder bed fusion (LPBF) and traditional computer numerical control (CNC) milling. A high-strength low-alloy steel (ER70S) mechanical part with medium complexity was fabricated using WAAM. Based on the data collected during this experiment, environmental impact and cost models were built using life cycle assessment and life cycle costing methodologies. WAAM was observed to be the most environmentally friendly option due to its superior material efficacy than CNC milling and has a better energy efficiency than LPBF. Also, WAAM was the most cost-friendly option when adopted in batch production for batch sizes above 3. The environmental and cost potential of WAAM is amplified when used for manufacturing large products, resulting in significant material, emission, and cost savings. The fabricated WAAM part demonstrated good mechanical properties comparable to that of cast/forged material. The methodology and experimental data presented in this study can be used to calculate environmental impacts and costs for other products and can be helpful to manufacturers in selecting the most ecofriendly and cost-efficient manufacturing process.DEMI - Departamento de Engenharia Mecânica e IndustrialUNIDEMI - Unidade de Investigação e Desenvolvimento em Engenharia Mecânica e IndustrialCENIMAT-i3N - Centro de Investigação de Materiais (Lab. Associado I3N)DCM - Departamento de Ciência dos MateriaisRUNKokare, SamruddhaShen, JiajiaFonseca, Pedro P.Lopes, João G.Machado, Carla M.Santos, Telmo G.Oliveira, João P.Godina, Radu2024-10-09T22:40:12Z2024-092024-09-01T00:00:00Zinfo:eu-repo/semantics/publishedVersioninfo:eu-repo/semantics/article23application/pdfhttp://hdl.handle.net/10362/173277eng0268-3768PURE: 98643358https://doi.org/10.1007/s00170-024-14144-zinfo:eu-repo/semantics/openAccessreponame:Repositório Científico de Acesso Aberto de Portugal (Repositórios Cientìficos)instname:Agência para a Sociedade do Conhecimento (UMIC) - FCT - Sociedade da Informaçãoinstacron:RCAAP2024-10-14T01:41:00Zoai:run.unl.pt:10362/173277Portal AgregadorONGhttps://www.rcaap.pt/oai/openairemluisa.alvim@gmail.comopendoar:71602024-10-14T01:41Repositório Científico de Acesso Aberto de Portugal (Repositórios Cientìficos) - Agência para a Sociedade do Conhecimento (UMIC) - FCT - Sociedade da Informaçãofalse
dc.title.none.fl_str_mv Wire arc additive manufacturing of a high-strength low-alloy steel part
environmental impacts, costs, and mechanical properties
title Wire arc additive manufacturing of a high-strength low-alloy steel part
spellingShingle Wire arc additive manufacturing of a high-strength low-alloy steel part
Kokare, Samruddha
CNC machining
Laser powder bed fusion
Life cycle assessment
Life cycle costing
Mechanical characterization
Wire arc additive manufacturing
Control and Systems Engineering
Software
Mechanical Engineering
Computer Science Applications
Industrial and Manufacturing Engineering
SDG 7 - Affordable and Clean Energy
SDG 12 - Responsible Consumption and Production
title_short Wire arc additive manufacturing of a high-strength low-alloy steel part
title_full Wire arc additive manufacturing of a high-strength low-alloy steel part
title_fullStr Wire arc additive manufacturing of a high-strength low-alloy steel part
title_full_unstemmed Wire arc additive manufacturing of a high-strength low-alloy steel part
title_sort Wire arc additive manufacturing of a high-strength low-alloy steel part
author Kokare, Samruddha
author_facet Kokare, Samruddha
Shen, Jiajia
Fonseca, Pedro P.
Lopes, João G.
Machado, Carla M.
Santos, Telmo G.
Oliveira, João P.
Godina, Radu
author_role author
author2 Shen, Jiajia
Fonseca, Pedro P.
Lopes, João G.
Machado, Carla M.
Santos, Telmo G.
Oliveira, João P.
Godina, Radu
author2_role author
author
author
author
author
author
author
dc.contributor.none.fl_str_mv DEMI - Departamento de Engenharia Mecânica e Industrial
UNIDEMI - Unidade de Investigação e Desenvolvimento em Engenharia Mecânica e Industrial
CENIMAT-i3N - Centro de Investigação de Materiais (Lab. Associado I3N)
DCM - Departamento de Ciência dos Materiais
RUN
dc.contributor.author.fl_str_mv Kokare, Samruddha
Shen, Jiajia
Fonseca, Pedro P.
Lopes, João G.
Machado, Carla M.
Santos, Telmo G.
Oliveira, João P.
Godina, Radu
dc.subject.por.fl_str_mv CNC machining
Laser powder bed fusion
Life cycle assessment
Life cycle costing
Mechanical characterization
Wire arc additive manufacturing
Control and Systems Engineering
Software
Mechanical Engineering
Computer Science Applications
Industrial and Manufacturing Engineering
SDG 7 - Affordable and Clean Energy
SDG 12 - Responsible Consumption and Production
topic CNC machining
Laser powder bed fusion
Life cycle assessment
Life cycle costing
Mechanical characterization
Wire arc additive manufacturing
Control and Systems Engineering
Software
Mechanical Engineering
Computer Science Applications
Industrial and Manufacturing Engineering
SDG 7 - Affordable and Clean Energy
SDG 12 - Responsible Consumption and Production
description Funding Information: Samruddha Kokare acknowledges Funda\u00E7\u00E3o para a Ci\u00EAncia e a Tecnologia (FCT\u2013MCTES) for its financial support via the MIT-Portugal Program PhD grant PRT/BD/154651/2023. Jiajia Shen acknowledges the China Scholarship Council for funding the Ph.D. grant CSC No. 201808320394. Pedro Fonseca acknowledges FCT\u2013MCTES for funding the PhD grant 2022.13883.BD. J.G. Lopes acknowledges FCT\u2013MCTES for its financial support via the Ph.D. grant 2020.07350.BD. J. P. Oliveira acknowledges funding by national funds from FCT\u2013Funda\u00E7\u00E3o para a Ci\u00EAncia e a Tecnologia, I.P., in the scope of the projects LA/P/0037/2020, UIDP/50025/2020, and UIDB/50025/2020 of the Associate Laboratory Institute of Nanostructures, Nanomodelling and Nanofabrication\u2013i3N. Samruddha Kokare, Radu Godina, Telmo G. Santos, and Carla M. Machado acknowledge Funda\u00E7\u00E3o para a Ci\u00EAncia e a Tecnologia (FCT\u2013MCTES) for its financial support for its financial support via the project UIDP/00667/2020 and UIDB/00667/2020 (UNIDEMI). This activity has received funding from the European Institute of Innovation and Technology (EIT)\u2013Project Smart WAAM: Microstructural Engineering and Integrated Non-Destructive Testing. This body of the European Union receives support from the European Union\u2019s Horizon 2020 research and innovation programme. Funding Information: Open access funding provided by FCT|FCCN (b-on). Samruddha Kokare acknowledges Funda\u00E7\u00E3o para a Ci\u00EAncia e a Tecnologia (Portugal) for its financial support via the MIT-Portugal Program PhD grant PRT/BD/154651/2023. Jiajia Shen acknowledges the China Scholarship Council for funding the Ph.D. grant CSC No. 201808320394. Pedro Fonseca acknowledges FCT\u2013MCTES for funding the PhD grant 2022.13883.BD. J.G. Lopes acknowledges FCT\u2013MCTES for its financial support via the Ph.D. grant 2020.07350.BD. J. P. Oliveira acknowledges funding by national funds from FCT\u2013Funda\u00E7\u00E3o para a Ci\u00EAncia e a Tecnologia, I.P., in the scope of the projects LA/P/0037/2020, UIDP/50025/2020, and UIDB/50025/2020 of the Associate Laboratory Institute of Nanostructures, Nanomodelling and Nanofabrication\u2013i3N. Samruddha Kokare, Radu Godina, Telmo G. Santos, and Carla M. Machado acknowledge Funda\u00E7\u00E3o para a Ci\u00EAncia e a Tecnologia (FCT-MCTES) for its financial support for its financial support via the project UIDP/00667/2020 and UIDB/00667/2020 (UNIDEMI). This activity has received funding from the European Institute of Innovation and Technology (EIT)\u2013Project Smart WAAM: Microstructural Engineering and Integrated Non-Destructive Testing. This body of the European Union receives support from the European Union\u2019s Horizon 2020 research and innovation programme. Publisher Copyright: © The Author(s) 2024.
publishDate 2024
dc.date.none.fl_str_mv 2024-10-09T22:40:12Z
2024-09
2024-09-01T00:00:00Z
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PURE: 98643358
https://doi.org/10.1007/s00170-024-14144-z
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