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HUMAN-INSPIRED WIRE ARC ADDITIVE MANUFACTURING WITHOUT SHIELDING GAS
Dissertation   Open access

HUMAN-INSPIRED WIRE ARC ADDITIVE MANUFACTURING WITHOUT SHIELDING GAS

Catherine F. Gosser
Washington State University
Doctor of Philosophy (PhD), Washington State University
12/2024
DOI:
https://doi.org/10.7273/000007198
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Abstract

additive manufacturing inner shield Welding
Wire arc additive manufacturing or three-dimensional printing has been utilized in various fully automated welding techniques to reduce the number of parts in complex assemblies and increase fabricator safety. In this investigation the conventional definitions of additive manufacturing are expanded to include self-shielding flux core arc welding. Wire arc additive manufacturing - flux-cored arc welding (WAAM-FCAW) with self-shielded wire E71T1-8 is automated using a Burny-5 fully automatic 3-axis gantry to create a single vee-groove joint in mild carbon steel plate via a novel infill pattern. To achieve a fully automated weldment in 19mm and 25mm carbon steel plates the infill patterns required a flat surface between layers, this innovative infill pattern creates a flat crown thus reducing the time and material required to fabricate a single joint. Three infill patterns are designed using a combination of human inspired type design in both x and y fill path direction. The infill patterns were assessed to AWS D1.1 standards by tensile, bend testing, and macro-imaging. The grain structure of the joints was evaluated with Electron Backscatter Diffraction, a scanning electron microscope technique.

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