摘要

电弧定向能量沉积 (WA-DED) 也称为电弧增材制造 (WAAM)，是一种适用于金属的利基增材制造技术，与传统的锻造和铸造方法相比，它越来越具有竞争优势。WA-DED 的特点是高沉积速率和与粉末工艺相比便宜的原料，使其在制造大型部件时非常高效。本文通过评估过程可扩展性的各个方面，回顾了 WA-DED 作为大型组件制造技术的情况。电弧工艺在其生产特性方面进行了比较，显示了每种电源的相对适用性。已经确定了可以减少缺陷并提高机械性能的其他原位工艺。对 WA-DED 工艺规划的调查揭示了通过防止整个制造过程中错误的累积可以节省材料的潜力。主要发现是，额外的原位工艺和工艺规划与闭环前馈控制系统相结合，可以在机械性能、几何可重复性和分辨率方面显着改善工艺。此外，人们发现，虽然通常研究机械性能的各向同性程度，但对机械性能异质性的研究是有限的，并且没有评估沉积材料内不同位置的拉伸性能。主要发现是，额外的原位工艺和工艺规划与闭环前馈控制系统相结合，可以在机械性能、几何可重复性和分辨率方面显着改善工艺。此外，人们发现，虽然通常研究机械性能的各向同性程度，但对机械性能异质性的研究是有限的，并且没有评估沉积材料内不同位置的拉伸性能。主要发现是，额外的原位工艺和工艺规划与闭环前馈控制系统相结合，可以在机械性能、几何可重复性和分辨率方面显着改善工艺。此外，人们发现，虽然通常研究机械性能的各向同性程度，但对机械性能异质性的研究是有限的，并且没有评估沉积材料内不同位置的拉伸性能。

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ABSTRACT

Wire Arc Directed Energy Deposition (WA-DED) also known as Wire Arc Additive Manufacture (WAAM) is a niche additive manufacturing technique for metals that is increasingly offering a competitive advantage to traditional forging and casting methods. Characteristics of WA-DED are high deposition rates and feedstock that is inexpensive compared to powder processes, making it highly efficient for manufacture of large components. This paper reviews WA-DED as a technique for large component manufacture by assessing aspects of the process scalability. Arc processes are compared in terms of their production characteristics showing the relative suitability of each power source. Additional in-situ processes have been identified that can alleviate defects and improve mechanical performance. Investigation of process planning for WA-DED has revealed the potential for material savings that can be achieved by preventing accumulation of errors throughout manufacture. The major finding is that additional in-situ processes and process planning combined with a closed loop feed forward control system can significantly improve the process in terms of mechanical performance, geometric repeatability and resolution. Additionally, it was found that although the degree of isotropy of mechanical performance is commonly investigated, research into the heterogeneity of mechanical performance is limited, and does not assess tensile properties at different locations within deposited material.