High Productivity Wire Arc Additive Manufacturing (HPWAAM)

高生产率电弧增材制造 (HPWAAM)

• 批准号: 53610
• 金额: $ 154.2万
• 依托单位: WEIR GROUP PLC(THE)
• 依托单位国家: 英国
• 项目类别: Study
• 财政年份: 2020
• 资助国家: 英国
• 起止时间: 2020 至 无数据
• 项目状态: 已结题
• 来源: https://gtr.ukri.org/projects?ref=53610
• 关键词: Productivity; Wire; Arc; Additive; Manufacturing

Additive Manufacturing (AM) also known as 3D printing is a process where objects are produced by adding and depositing material in layers. AM offers significant advantages over traditional manufacturing namely design freedom,lead time reduction and lightweighting resulting to increased performance, cost reduction and new business models-digital inventories.Most AM systems comprise of a motion system, heat source and feedstock(raw material). Wire Arc Additive Manufacturing (WAAM) is the combining of a robotic manipulator, using an electric arc as the heat source and wire as the feedstock. WAAM also offers the distinct advantage of being able to produce near-net shape designs in a large scale \\\>1m long.Currently WAAM is focused on high value parts weighing a few tens of kg made out materials such as titanium for the aerospace sector. Current build rates for WAAM are quite low at 2-3 kg/hr. Other industry sectors such as mining, energy and construction use lower value materials e.g. steels and are showing interest in WAAM application. In these industries the production processes are casting, forging combined with machining and/or fabrication reliant on manual operations. Parts often weigh several hundred kgs or even tons, with lengthy production time frames. To make a viable business case for WAAM in these industries, the deposition rate needs to increase dramatically to \\\>15kg/hr for steel, whilst maintaining precision and low recurring costs.In this project a new High Productivity Wire Arc Additive Manufacturing Process (HPWAAM) will be developed to manufacture large scale parts and structures used in engineering and construction industries with high quality and deposition rate of up to 15 kg/hr. To help achieve this new high-quality shaped filler wires (Wintwire-SME) and overall heat control using cryogenic cooling (BOC) will also be developed.**Aim** Demonstrate a new High Productivity Wire Arc Additive Manufacturing process for manufacturing large components and structures for mining, oil&gas and construction industries.**Objectives**Industrialise the HPWAAM process for large-scale engineering components,featuring full thermal control and variable resolution (CU, WAAM3D-SME).Upgrade existing planning and control software to commercial grade enabling implementation of HPWAAM in an industrial environment.Demonstrate the capabilities of HPWAAM for production of \\\>100kg steel components for mining and construction applications.Led by Weir Group this challenging project consists of a consortium covering all aspects necessary for industrial implementation of HPWAAM; process technology development (CU, BOC), supply chain (WAAM3D, Wintwire), end users (Weir, Fosters+Partners) and steel fabrication supplier (Steelo-SME).

增材制造（AM）也称为3D打印，是一种通过添加和沉积材料层来生产物体的过程。与传统制造相比，增材制造具有显著的优势，即设计自由度、缩短交货期和轻量化，从而提高性能、降低成本和新的商业模式-数字库存。大多数增材制造系统由运动系统、热源和原料（原材料）组成。线弧增材制造（WAAM）是一个机器人机械手的组合，使用电弧作为热源和电线作为原料。WAAM还提供了能够生产近净形设计的大规模的独特优势\ WAAM目前的建造速度非常低，为2-3公斤/小时。其他工业部门，如采矿、能源和建筑，使用价值较低的材料，如钢材，并对WAAM的应用表现出兴趣。在这些行业中，生产过程是铸造、锻造与机械加工和/或依赖于人工操作的制造相结合。零件通常重达几百公斤甚至几吨，生产时间很长。为了使WAAM在这些行业中成为可行的商业案例，钢的沉积速率需要大幅增加到15 kg/hr，同时保持精度和低经常性成本。在该项目中，一种新的高生产率电弧增材制造工艺（HPWAAM）将开发用于制造工程和建筑行业的大规模零件和结构，具有高质量和沉积速率高达15 kg/hr。为了帮助实现这一目标，还将开发新型高质量异形填充焊丝（Wintwire-SME）和使用低温冷却（BOC）的整体热控制。**目的 ** 展示一种新的高生产率电弧增材制造工艺，用于制造采矿、石油和天然气以及建筑行业的大型部件和结构。**目标 ** 实现大规模工程部件HPWAAM工艺的工业化，具有全面的热控制和可变分辨率（CU，WAAM 3D-SME）。将现有的计划和控制软件升级到商业级，使HPWAAM能够在工业环境中实施。演示HPWAAM生产用于采矿和建筑应用的100公斤钢构件。由威尔集团牵头，这个具有挑战性的项目由一个财团组成，涵盖了HPWAAM工业实施所需的所有方面;过程技术开发（CU、BOC）、供应链（WAAM 3D、Wintwire）、最终用户（Weir、Fosters+Partners）和钢结构制造供应商（Steelo-SME）。