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Development of a cold wire-feed additive layer manufacturing system using shaped metal deposition method

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Abstract

Shaped metal deposition (SMD) method would be an alternative way to traditional manufacturing methods, especially for complex featured and large scale solid parts and it is particularly used for aerospace structural components, manufacturing and repairing of die/molds and middle-sized dense parts. This method is implemented by depositing continuous cold or hot-water melted via welding arc plasma heat. This paper presents the designing, constructing, and controlling of an additive manufacturing system using TIG plus wire based Shaped metal deposition (TW-SMD) method. The aim of the current study is to design and develop an integrated system which is able to reduce time consuming and boring task of deposition process. The developed additive system is capable of producing near net shaped components of sizes not exceed 400 mm in 3 directions directly from CAD drawing. The results showed that the developed system succeeded to produce near net geometries and error-free depositions for various features of SS308LSi components. Additionally, workshop tests have been conducted in order to verify the capability and reliability of the developed AM system.

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Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Faculty of Engineering, Advanced Manufacturing Technology Research Group, Gazi University, 06570, Maltepe, Ankara, Turkey

    Oguzhan Yilmaz

  2. Department of Mechanical Engineering, College of Engineering, University of Thi-Qar, Al-Nasiriyah, Iraq

    Adnan A. Ugla

Authors
  1. Oguzhan Yilmaz
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  2. Adnan A. Ugla
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Correspondence to Adnan A. Ugla.

Additional information

Recommended by Associate Editor Vikas Tomar

Adnan A. Ugla received the M.Sc. degree in mechanical engineering from the University of Baghdad, Baghdad, Iraq, in 2003, and the Ph.D. degree in mechanical engineering from the University of Gaziantep, Gaziantep, Turkey. He is an Assistant Professor in Engineering Faculty of Thi-Qar University in Al-Nasiriyah, Iraq. Assistant Prof. Ugla is member of Advanced Manufacturing Technology Research Group and his research interests mainly cover additive manufacturing, welding based shaped metal deposition, welding processes and quality control. He has published journal papers and participated some of international conferences in the same area.

Oguzhan Yilmaz is currently an Associate Professor in Engineering Faculty of Gazi University in Ankara, Turkey. Prof. Yilmaz is the Head of Advanced Manufacturing Technology Research Group and his research interests mainly cover additive manufacturing, welding based shaped metal deposition and nontraditional machining processes. He involved many research projects and has published journal papers in the same area. Prof. Yilmaz is also Editor-in-Chief of the Journal of Faculty of Engineering and Architecture of Gazi University.

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Yilmaz, O., Ugla, A.A. Development of a cold wire-feed additive layer manufacturing system using shaped metal deposition method. J Mech Sci Technol 31, 1611–1620 (2017). https://doi.org/10.1007/s12206-017-0308-9

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  • DOI: https://doi.org/10.1007/s12206-017-0308-9

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