Researchers at the University of Sheffield, UK, are developing a new additive manufacturing technique that aims to minimise the presence of residual stresses in components. The project, funded by EPSRC UK, aims to develop a novel, low cost metallic Additive Manufacturing process that induces low thermal stress during manufacturing: Layered Extrusion of Metal Alloys (LEMA).
What happens when you combine in a single setup the benefits of WAAM with in-process grain refinement, online monitoring and final machining? You could end up with an attractive commercial opportunity to make large aerospace components at reasonable price. In the first article of this two-part series, we present a ‘ready to use’ additive manufacturing technology. The second part will address typical costs and applications.
Cold spray is a technique that accelerates powder particles towards a substrate using a supersonic compressed gas jet. Upon impact, the particles travelling at high velocities (200 to 1000m.s-1) experience extreme and rapid plastic deformation. They stack up to form a solid state deposit that is well bonded to the substrate and free of oxides (disturbed at impact).
In wire-feed AM, a metal wire is used as supply material to build components – typically large ones of moderate complexity. Depending on the energy source used for deposition, wire-feed AM can be classified into three groups: wire and laser additive manufacturing (WLAM), electron beam freeform fabrication (EBF3) and wire and arc additive manufacturing (WAAM) [1, 2].
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