ECCOMAS 2024

Numerical Analysis of In-Situ Cooling Strategies in Wire Arc Additive Manufacturing for Enhanced Process Efficiency

  • Reindl, Thomas (Technical University of Munich)
  • Hempel, Nico (Technical University of Munich)
  • Mayr, Peter (Technical University of Munich)

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Additive Manufacturing with metals has been gaining increasing industrial interest for decades, as reflected in the continuous expansion of its application fields. In contrast to typical powder-bed-based technologies, such as Powder Bed Fusion – Laser Beam (PBF-LB), Wire Arc Additive Manufacturing (WAAM) can be used to generate large-volume components with significantly higher deposition rates. Despite many advantages, there are still challenges regarding the control of heat input in WAAM. For example, heat accumulations may occur during component production, necessitating the implementation of process pauses as cooling phases. This leads to a reduction in process efficiency, which also prevents WAAM from becoming further established in the industry. This results in the need for new and more efficient active in-situ cooling strategies to reduce process time and ensure mechanical properties. In this work, different in-situ cooling strategies with the aim of preventing heat accumulation during the WAAM process and enhancing the process efficiency are investigated. For this purpose, numerical analyses were conducted using the simulation software Simufact Welding to examine the influences of different global and local cooling strategies. The simulation methodology was validated by comparing the simulated thermal behavior with experimentally obtained temperature values, which were measured using a thermal imaging camera and thermocouples. The maximum effects of the different in-situ cooling strategies on the interpass temperatures and the achievable cooling rates were numerically determined and compared. The results can be used to evaluate the potential savings in process time, clarifying how strategic cooling can enhance the efficiency of WAAM by systematically decreasing heat accumulation. These findings are fundamental for developing and implementing in-situ cooling strategies in WAAM to improve process efficiency, secure part quality, and mark a step towards further industrialization.