Villanueva Roldán, Pedro
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Villanueva Roldán
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Pedro
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Ingeniería
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Publication Open Access Advancements and methodologies in directed energy deposition (DED-Arc) manufacturing: design strategies, material hybridization, process optimization and artificial intelligence(IntechOpen, 2024-09-27) Uralde Jiménez, Virginia; Suárez, Alfredo; Veiga Suárez, Fernando; Villanueva Roldán, Pedro; Ballesteros Egüés, Tomás; Ingeniería; Ingeniaritza; Institute of Smart Cities - ISCThis chapter explores the latest advancements and methodologies in directed energy deposition (DED-arc) manufacturing. The introduction sets the stage for understanding the significance of these developments in the context of modern manufacturing needs. The discussion includes design strategies for DED-arc, emphasizing topological optimization, functional design, and generative design, alongside the application of artificial intelligence (AI) in enhancing design processes. Innovative approaches to material hybridization are detailed, focusing on both multilayer and in situ techniques for combining different materials to optimize component performance. The paper also covers slicing and pathing, examining slicing strategies, the use of lattice structures, and the implementation of 2D and 3D patterns to improve manufacturing efficiency and product quality. The conclusion summarizes key findings, discusses their implications for the additive manufacturing industry, and suggests potential future research directions in DED-arc technology, highlighting the emerging trends and innovations that are shaping the field.Publication Open Access Benefits of aeronautical preform manufacturing through arc-directed energy deposition manufacturing(MDPI, 2023) Suárez, Alfredo; Ramiro, Pedro; Veiga Suárez, Fernando; Ballesteros Egüés, Tomás; Villanueva Roldán, Pedro; Ingeniería; IngeniaritzaThe paper introduces an innovative aerospace component production approach employing Wire Arc Additive Manufacturing (WAAM) technology to fabricate near-finished preforms from Ti6Al4V titanium. Tensile tests on WAAM Ti6Al4V workpieces demonstrated reliable mechanical properties, albeit with identified anisotropic behavior in horizontal samples, underscoring the need for optimization. This alternative manufacturing strategy addresses the challenges associated with machining forged preforms, marked by a high Buy To Fly (BTF) ratio (>10), leading to material wastage, prolonged machining durations, elevated tool expenses, and heightened waste and energy consumption. Additionally, logistical and storage costs are increased due to extended delivery timelines, exacerbated by supply issues related to the current unstable situation. The utilization of WAAM significantly mitigates initial BTF, preform costs, waste production, machining durations, and associated expenditures, while notably reducing lead times from months to mere hours. The novelty in this study lies in the application of Wire Arc Additive Manufacturing (WAAM) technology for the fabrication of titanium aircraft components. This approach includes a unique height compensation strategy and the implementation of various deposition strategies, such as single-seam, overlapping, and oscillating.