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Search Results (5)

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Keywords = Laser Wire-Feed Additive Manufacturing (LWAM)

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19 pages, 5719 KiB  
Article
Influence of Laser-Wire Metal Deposition Process Parameters on the Mechanical Properties and Microstructure of ER70S-6 Steel
by Daniel Gomez-Lendinez, Jesus Garcia-Moreno-Caraballo, Sergio Corbera and Rafael Barea
J. Manuf. Mater. Process. 2025, 9(5), 157; https://doi.org/10.3390/jmmp9050157 - 9 May 2025
Viewed by 857
Abstract
Low-carbon steels, such as ER70S-6, are typically considered resistant to phase transformations due to their high critical cooling rate. However, this study investigates how the manufacturing process and specimen geometry influence heat dissipation, potentially leading to localized grain size variations that impact mechanical [...] Read more.
Low-carbon steels, such as ER70S-6, are typically considered resistant to phase transformations due to their high critical cooling rate. However, this study investigates how the manufacturing process and specimen geometry influence heat dissipation, potentially leading to localized grain size variations that impact mechanical properties. To analyze these effects, samples were fabricated using Laser Wire-Feed Additive Manufacturing (LWAM) with different geometries, and their hardness and microstructural characteristics were evaluated. Vickers microhardness tests were performed along the specimens to assess local variations, while dilatometry measurements were conducted to determine thermal expansion coefficients for future integration into finite element models (FEMs) of residual stress distribution. The results reveal that differences in heat dissipation during fabrication lead to grain size heterogeneity, affecting hardness at a microscopic scale and overall mechanical performance. These findings highlight the importance of considering thermal history and geometry in LWAM-fabricated components to ensure consistent material properties. Full article
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18 pages, 5769 KiB  
Article
Investigating the Impact of Process Parameters on Bead Geometry in Laser Wire-Feed Metal Additive Manufacturing
by Mohammad Abuabiah, Tizia Charlotte Weidemann, Mahdi Amne Elahi, Bahaa Shaqour, Robin Day, Peter Plapper and Thomas Bergs
J. Manuf. Mater. Process. 2024, 8(5), 204; https://doi.org/10.3390/jmmp8050204 - 19 Sep 2024
Viewed by 2134
Abstract
Laser wire-feed metal additive manufacturing (LWAM) is an innovative technology that shows many advantages compared with traditional manufacturing approaches. Despite these advantages, its industrial adoption is limited by complex parameter management and inconsistent process quality. To address these issues and improve geometric accuracy, [...] Read more.
Laser wire-feed metal additive manufacturing (LWAM) is an innovative technology that shows many advantages compared with traditional manufacturing approaches. Despite these advantages, its industrial adoption is limited by complex parameter management and inconsistent process quality. To address these issues and improve geometric accuracy, this study explores how process parameters influence bead geometry. We conducted a parameter study varying laser power, wire feed rate, traverse speed, and welding angle. Using a full factorial design with a central composite design methodology, we assessed bead height and width. This allowed us to develop a model to estimate ideal process parameters. The findings offer a detailed analysis of parameter interactions and their effects on bead geometry, aiming to enhance geometric accuracy and process stability in LWAM. Moreover, we have evaluated the proposed process parameters from our developed model, which showed a significant enhancement to the overall quality. This was validated via printing a single layer and multi-layer structures. The quality of the final predicted sample using the proposed method was improved by 40% compared to the best sample produced for the Design of Experiment trials. Full article
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23 pages, 3351 KiB  
Review
Advancements in Laser Wire-Feed Metal Additive Manufacturing: A Brief Review
by Mohammad Abuabiah, Natago Guilé Mbodj, Bahaa Shaqour, Luqman Herzallah, Adel Juaidi, Ramez Abdallah and Peter Plapper
Materials 2023, 16(5), 2030; https://doi.org/10.3390/ma16052030 - 1 Mar 2023
Cited by 45 | Viewed by 7826
Abstract
Laser Wire-Feed Metal Additive Manufacturing (LWAM) is a process that utilizes a laser to heat and melt a metallic alloy wire, which is then precisely positioned on a substrate, or previous layer, to build a three-dimensional metal part. LWAM technology offers several advantages, [...] Read more.
Laser Wire-Feed Metal Additive Manufacturing (LWAM) is a process that utilizes a laser to heat and melt a metallic alloy wire, which is then precisely positioned on a substrate, or previous layer, to build a three-dimensional metal part. LWAM technology offers several advantages, such as high speed, cost effectiveness, precision control, and the ability to create complex geometries with near-net shape features and improved metallurgical properties. However, the technology is still in its early stages of development, and its integration into the industry is ongoing. To provide a comprehensive understanding of the LWAM technology, this review article emphasizes the importance of key aspects of LWAM, including parametric modeling, monitoring systems, control algorithms, and path-planning approaches. The study aims to identify potential gaps in the existing literature and highlight future research opportunities in the field of LWAM, with the goal of advancing its industrial application. Full article
(This article belongs to the Special Issue Advances in Additive Manufacturing (Volume II))
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18 pages, 9736 KiB  
Article
Modeling and Control of Layer Height in Laser Wire Additive Manufacturing
by Natago Guilé Mbodj, Mohammad Abuabiah, Peter Plapper, Maxime El Kandaoui and Slah Yaacoubi
Materials 2022, 15(13), 4479; https://doi.org/10.3390/ma15134479 - 25 Jun 2022
Cited by 10 | Viewed by 3564
Abstract
Laser Wire Additive Manufacturing (LWAM) is a flexible and fast manufacturing method used to produce variants of high metal geometric complexity. In this work, a physics-based model of the bead geometry including process parameters and material properties was developed for the LWAM process [...] Read more.
Laser Wire Additive Manufacturing (LWAM) is a flexible and fast manufacturing method used to produce variants of high metal geometric complexity. In this work, a physics-based model of the bead geometry including process parameters and material properties was developed for the LWAM process of large-scale products. The developed model aimed to include critical process parameters, material properties and thermal history to describe the relationship between the layer height with different process inputs (i.e., the power, the standoff distance, the temperature, the wire-feed rate, and the travel speed). Then, a Model Predictive Controller (MPC) was designed to keep the layer height trajectory constant taking into consideration the constraints faced in the LWAM technology. Experimental validation results were performed to check the accuracy of the proposed model and the results revealed that the developed model matches the experimental data. Finally, the designed MPC controller was able to track a predefined layer height reference signal by controlling the temperature input of the system. Full article
(This article belongs to the Special Issue Monitoring and Control in Additive Manufacturing Processes)
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17 pages, 5389 KiB  
Article
Bead Geometry Prediction in Laser-Wire Additive Manufacturing Process Using Machine Learning: Case of Study
by Natago Guilé Mbodj, Mohammad Abuabiah, Peter Plapper, Maxime El Kandaoui and Slah Yaacoubi
Appl. Sci. 2021, 11(24), 11949; https://doi.org/10.3390/app112411949 - 15 Dec 2021
Cited by 29 | Viewed by 5690
Abstract
In Laser Wire Additive Manufacturing (LWAM), the final geometry is produced using the layer-by-layer deposition (beads principle). To achieve good geometrical accuracy in the final product, proper implementation of the bead geometry is essential. For this reason, the paper focuses on this process [...] Read more.
In Laser Wire Additive Manufacturing (LWAM), the final geometry is produced using the layer-by-layer deposition (beads principle). To achieve good geometrical accuracy in the final product, proper implementation of the bead geometry is essential. For this reason, the paper focuses on this process and proposes a layer geometry (width and height) prediction model to improve deposition accuracy. More specifically, a machine learning regression algorithm is applied on several experimental data to predict the bead geometry across layers. Furthermore, a neural network-based approach was used to study the influence of different deposition parameters, namely laser power, wire-feed rate and travel speed on bead geometry. To validate the effectiveness of the proposed approach, a test split validation strategy was applied to train and validate the machine learning models. The results show a particular evolutionary trend and confirm that the process parameters have a direct influence on the bead geometry, and so, too, on the final part. Several deposition parameters have been found to obtain an accurate prediction model with low errors and good layer deposition. Finally, this study indicates that the machine learning approach can efficiently be used to predict the bead geometry and could help later in designing a proper controller in the LWAM process. Full article
(This article belongs to the Special Issue Metal Additive Manufacturing and its Applications: From the Material to Components Service Life)
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