Additive Manufacturing of Large Functional Parts Using Wire Directed Energy Deposition (DED)

全球添加剂制造市场正在增长，并有望在2027年达到410亿美元。与添加剂制造相关的设计灵活性使工业能够降低制造成本，减少温室气体排放，并促进净零排放经济。火用解决方案是一家总部位于艾伯塔省的能源和气候技术解决方案提供商，也是将金属添加剂制造作为一项先进技术的先驱之一。他们发现了一个目前尚未得到满足的客户需求，即采用加法制造比现有设备可以打印的部件大得多的部件。为了满足这一需求，火用和SAIT正在合作开发一种新兴的添加剂制造技术作为解决方案：送丝定向能量沉积(DED)。使用线材DED代替铸件，消除了高成本和相关的交货期，并引入了快速设计、印刷、测试和改进的灵活性。在该项目期间获得的知识和数据将加强加拿大在一个关键的新兴制造领域的专业知识，即使用焊丝DED系统进行大型复杂功能部件的添加制造。该项目开发的优化方法可用于能源和航空航天等部门，并将加快加拿大新的添加剂制造计划。

The global Additive Manufacturing market is increasing and on track to reach $41 billion USD by 2027. The design flexibility associated with additive manufacturing allows for industries to lower manufacturing costs, reduce GHG emissions and foster a net-zero emission economy. Exergy Solutions is an Alberta-based energy and climate technology solutions provider, and one of the pioneers in employing metal additive manufacturing as an advanced technique. They have discovered a currently unmet customer demand to employ additive manufacturing for much larger parts than what can be printed with existing equipment. To meet this demand, Exergy and SAIT are collaborating on an emerging additive manufacturing technology as a solution: wire fed directed energy deposition (DED). The use of wire DED to replace castings eliminates the high cost and associated lead time, and introduces the flexibility to rapidly design, print, test and improve. The knowledge and data acquired during this project will strengthen Canada's expertise in a key emerging manufacturing area of additive manufacturing of large complex functional parts using wire DED systems. The optimization methodology developed in this project can be used by sectors such as energy and aerospace and will accelerate novel additive manufacturing initiatives in Canada.