Rapid prototyping of metal parts by three-dimensional welding

TLDR

Three‑dimensional welding can produce strong, fully dense metal parts layer by layer, but high heat inputs may compromise part quality. The study aims to use simple temperature‑control techniques to improve surface finish. The authors fabricated parts with integrated temperature control, described the welding system, and employed surface‑measurement and residual‑stress assessment methods. The adapted weld‑cladding technique produced wider parts than single beads, and while temperature control improved surface finish, it also increased build time, with temperature–time, surface‑finish–temperature, and temperature–residual‑stress relationships quantified.

Abstract

Three-dimensional welding has the ability to produce strong, fully dense metal parts in layers. Adaptation of a weld cladding technique has enabled the production of parts wider than normally possible from single beads. However, high heat inputs during welding could affect part quality. Simple temperature control techniques help improve surface finish. A number of parts were made incorporating temperature control. Results show that, although improvements have been made, corresponding time penalties can have a significant influence on build time. Descriptions of the welding system and temperature control technique are included as well as the surface measurement and residual stress assessment techniques used. Results of temperature versus time, surface finish versus temperature and temperature versus residual stress are presented and discussed.