Additive Manufacturing using Advanced Robotics and Arc Metal Welding

Wire-Arc Additive Manufacturing (WAAM) is the metal additive manufacturing method with the highest deposition rate and can be used to manufacture the largest fabricated structures of any metal additive process. However, the process is not without its challenges in areas such as thermal management, defect generation, and residual stress.

Many of these problems can be overcome with a focused research plan that investigates the interaction of the advanced robotic welding technology with the metal alloys being deposited. This research project will focus on an experimental approach to solving the dedicated problems of defect elimination and residual stress management within the manufactured parts. The research will look at ways to improve the processing of the material during the additive manufacturing process and through post processing with heat treatment methods. A particular focus will be placed on microstructure formation (prediction and analyses) throughout the complete process cycle and the effect microstructure on the mechanical properties of the final components.

The successful candidate will build upon previous work completed within the School on thin-walled, stiffening features additively manufactured onto steel structures. In addition to the material properties, a focus will be placed on exploring the full envelope of possible geometries that can be created using the WAAM process through offline robotic programming technology.