Open Access
Wire arc additive manufacturing of invar parts: bead geometry and melt pool monitoring
(Elsevier, 2022-02-15) Veiga Suárez, Fernando; Suárez, Alfredo; Aldalur, Eider; Artaza, Teresa; Ingeniería; Ingeniaritza
Additive manufacturing processes using the direct energy deposition method, one of which is the Wire Arc Additive Manufacturing (WAAM), have gained much attention in the scientific community over the last decade. The application of WAAM to Invar, an iron-nickel and manganese alloy, with a low amount of chromium carbon, also called FeNi36 or Nivarox has been the subject of various reports due to its challenging nature. This paper utilizes and unifies research material previously investigated in this technology, taking a new approach based on the study of symmetrical phenomena that guarantee the quality of the process. On the one hand, a method of analysis of the geometry of the manufactured wall is presented based on its symmetrical quality which guarantees the maximum use of material and, on the other hand, the monitoring of the symmetry of the melting pool utilizing thermography techniques.
Open Access
Effect of the heat input on wire-arc additive manufacturing of invar 36 alloy: microstructure and mechanical properties
(Springer, 2022) Veiga Suárez, Fernando; Suárez, Alfredo; Artaza, Teresa; Aldalur, Eider; Ingeniería; Ingeniaritza; Universidad Pública de Navarra / Nafarroako Unibertsitate Publikoa
Invar, also known as FeNi36, is a material of great interest due to its unique properties, which makes it an excellent alternative for sectors such as tooling in aeronautics and aerospace. Its manufacture by means of wire arc additive manufacturing (WAAM) technology could extend its use. This paper aims to evaluate the comparison of two of the most widespread WAAM technologies: plasma arc welding (PAW) and gas metal arc welding (GMAW). This comparison is based on the analysis of wall geometry, metallography, and mechanical properties of the material produced by both technologies. The results show a slight increase in toughness and elongation before fracture and worse tensile strength data in the case of PAW, with average values of 485 MPa for ultimate tensile strength (UTS), 31% for elongation and 475 MPa, 40% in GMAW and PAW, respectively. All results gathered from the analysis show the possibility of successful manufacturing of Invar by means of WAAM technologies. The novelties presented in this paper allow us to establish relationships between the thermal input of the process itself and the mechanical and metallographic properties of the material produced.
Open Access
Wire arc additive manufacturing of an aeronautic fitting with different metal alloys: from the design to the part
(Elsevier, 2021-01-29) Suárez, Alfredo; Aldalur, Eider; Veiga Suárez, Fernando; Artaza, Teresa; Tabernero, Iván; Lamikiz, Aitzol; Ingeniería; Ingeniaritza
WAAM (Wire Arc Additive Manufacturing), an additive manufacturing technology with high deposition rates, can produce metallic components, layer by layer, from different alloys, yielding high mechanical performance. Customized AM machines with monitoring and control systems are necessary to facilitate automated manufacture of different types of components through WAAM technology. In this paper, a methodology for the validation of additive manufacturing is presented as an alternative to industrial machining, for the manufacture of medium-sized aeronautical parts. To begin with, the most appropriate welding technology and adequate parameters for four different metal alloys are selected. Successively, a characterization wall is manufactured with each of the four metal alloys, for metallographic and mechanical characterization, concluding that the material deposited utilizing the WAAM process is adequate for the fabrication of medium-sized aeronautical parts. Consecutively, machine paths are defined under conditions that consume the least possible amount of material for the manufacturing of the aeronautical part. Several aspects -manufacturing times, deposition rate, material efficiency ratio- of each component are then analyzed, relating them to the properties obtained in each alloy. The manufacturing process is supervised and controlled by online monitoring. The novelty of this paper consists in establishing unique dataset for each component that is defined as a unique additive manufacturing Fingerprint as baseline for in process defect detection. Finally, the unique contribution of stablishing a matrix-strategy for the manufacture of multiple parts with the same tooling to optimize the use of resources is presented.

Veiga Suárez, Fernando

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