High Productivity Wire Arc Additive Manufacturing (HPWAAM)

增材制造（AM）也被称为3D打印，是一种通过分层添加和沉积材料来生产物体的过程。与传统制造相比，增材制造具有显著的优势，即设计自由、缩短交货时间和轻量化，从而提高了性能、降低了成本和新的商业模式——数字化库存。大多数增材制造系统由运动系统、热源和原料（原料）组成。电弧增材制造（WAAM）是一种以电弧为热源，以导线为原料的机器人机械臂的结合。WAAM还提供了独特的优势，能够在大规模\\\> m长上生产近净形状设计。目前，WAAM专注于航空航天领域用钛等材料制造的重达几十公斤的高价值部件。目前WAAM的构建速率非常低，为2-3千克/小时。其他工业部门，如采矿、能源和建筑使用较低价值的材料，如钢铁，并对WAAM的应用表现出兴趣。在这些行业的生产过程是铸造，锻造结合机械加工和/或制造依赖于手工操作。零件通常重达数百公斤甚至吨，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，沉积速率需要大幅提高到15kg/hr，同时保持精度和低重复成本。在该项目中，将开发一种新的高生产率线弧增材制造工艺（HPWAAM），以制造用于工程和建筑行业的大型零件和结构，其高质量和沉积速度高达15公斤/小时。为了实现这一目标，还将开发新的高质量形状填充线（Wintwire-SME）和使用低温冷却（BOC）的整体热控制。**目标**展示一种新的高生产率线弧增材制造工艺，用于制造采矿、石油天然气和建筑行业的大型部件和结构。**目标**工业化大规模工程部件的HPWAAM工艺，具有全热控制和可变分辨率（CU, WAAM3D-SME）。将现有的规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为采矿和建筑应用生产100公斤钢部件的能力。在Weir集团的领导下，这个具有挑战性的项目由一个涵盖HPWAAM工业实施所需的所有方面的财团组成；工艺技术开发（CU， BOC），供应链（WAAM3D, Wintwire），最终用户（Weir, Fosters+Partners）和钢铁制造供应商（Steelo-SME）。

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).