Wire-based additive manufacturing (AM) is opening a new era in metal AM. It is gaining attention in major sectors like aerospace, nuclear, tooling and more due to its potential to produce large-scale components with higher build-rates compared to powder-based AM systems. Standard welding processes such as gas metal arc, gas tungsten arc, plasma arc, laser or electron-beam, can be applied in wire-based AM with only slight adaptions. Furthermore, the development of wire-based AM is being driven by the need for increased manufacturing efficiency of engineering structures. Development activities involving wire-based AM of different materials, however, are relatively limited to date compared to powder-based AM. Wire-based AM challenges include (but are not limited to) difficulties in developing the right process parameters and tool-paths to avoid defects, finding options for in-situ monitoring, investigating algorithms to compensate geometric and thermal effects, and outstanding issues regarding material properties and repeatability. These may need to be addressed in specific ways for particular materials in order to achieve fully automated systems. This presentation will summarize the current knowledge of wire-based AM with emphasis on system configurations, materials applied, mechanical properties achieved, and provide options to overcome challenges mentioned above.
- Understand the advantages and applicability of different wire-based AM processes.
- Know current research and challenges in wire-based AM systems around the world
- Know the options in dealing with challenges in wire-based AM processes to make these processes more automated