Year

2019

Degree Name

Master of Philosophy

Department

School of Mechanical, Materials, Mechatronic and Biomedical Engineering

Abstract

Wire Arc Additive Manufacturing (WAAM) is an up-and-coming process for manufacturing complex metallic products due to its high deposition rate and rapid prototyping capabilities. To enhance the ability of the WAAM process to fabricate workpieces with high spatial complexity geometry, this thesis proposes theWAAM strategy that is particularly suitable to produce freeform wire-structured parts.

Contributions in this thesis mainly include a bead modelling study for finding the suitable welding parameter combination and establish optimal welding parameters range, and an innovative deposition strategy, which the main functions include an adaptive slicing methodology and height control system.

In this thesis, the effectiveness and reliability of this approach are demonstrated through the fabrication process of a honeycomb structure workpiece of the 2D plane, a cube structure workpiece in the 3D space, and various simple wire-structure part samples for demonstration. With the current results described in this thesis, the proposed strategy requires less processing time and rarely requires manual intervention to manufacture the wire-structured part, which dramatically reduces the difficulty of processing workpieces with these complex wirestructured geometries, and it will have broader application in the future.

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Unless otherwise indicated, the views expressed in this thesis are those of the author and do not necessarily represent the views of the University of Wollongong.