Dissemination DeliverablesD5.1

Deliverable 5.1

Abstract

Deliverable 5.1 aims at providing the requirements and needs for modelling and experimental approaches to be developed within the CIRCULAR WELD project. To achieve such goal, a comprehensive analysis of the dot-by-dot Wire Arc Additive Manufacturing (WAAM) process is presented. The document is structured into three main sections: State of the Art Analysis, Methodologies, and Requirements, each encompassing detailed subsections that investigate the specific results of the project: Geometrical Model, Thermo-Mechanical Model, Monitoring solution, Microstructure-Mechanical Model, Mechanical-Structural Model.

In the State of the Art Analysis, current literature is analyzed to form the basis for methodology and requirements sections. In detail the document presents geometrical modelling and characterization, highlighting the current techniques, both experimental and analytical in modeling dot-by-dot WAAM parts. This is followed by an in-depth exploration of thermo-mechanical simulation, including details for accurate simulation of the WAAM process. Then, the document reviews the various monitoring solutions used to ensure the quality and consistency of WAAM parts. Additionally, the microstructure-mechanical modelling and characterization section examines the relationship between microstructural features and mechanical properties, while the mechanical-structural modelling and characterization section investigates the potential of WAAM for large-scale structural applications, including the lifecycle assessment (LCA) of the process/product.

The Methodologies section outlines the specific methods and techniques that will be used in the project for its final outcomes, including the modeling approaches that will be adopted and instruments that will be used for the experimental validation. In addition, some details on structural element and unit cell are presented.

Finally, the Requirements section specifies the manufacturing and product requirements for dot-by-dot WAAM bars considered in the project. At the beginning of this section, the results of the first batch of dot-by-dot bars are presented to support the requirement definition. The definition of the requirements provided in this document form the basis for the development of the CIRCULAR WELD project main results.

Table of contents

1.     STATE OF THE ART ANALYSIS OF DOT-BY-DOT WAAM PROCESS AND PRODUCT

1.1        Geometrical modelling and characterization

1.1.1     Geometrical modelling of dot-by-dot WAAM parts

1.1.2     Geometrical characterization of dot-by-dot WAAM parts

1.2        Thermo-mechanical simulation

1.2.1     Geometrical Discretization

1.2.2     Heat Source

1.2.3     Boundary Conditions

1.2.4     Analysis type

1.2.5     Temperature-Dependent Material Properties

1.2.6     Thermo-mechanical simulation of dot-by-dot WAAM

1.3        Monitoring solutions

1.3.1     Infrared (IR) Thermography

1.3.2     Pyrometry

1.3.1     Thermocouples

1.4        Microstructure-Mechanical modelling and characterization

1.4.1     Microstructural features and mechanical properties of WAAM parts

1.4.2     Characterization and modeling of microstructural features of WAAM parts

1.5        Mechanical-Structural modelling and characterization

1.5.1     Potential of WAAM for large-scale structural engineering applications

1.5.2     Layer-by-layer WAAM elements: research studies and applications

1.5.3     Dot-by-dot WAAM elements: research studies and applications

1.5.4     Strengthening and repairing using WAAM

1.5.5     LCA assessment of WAAM structural elements

2.     METHODOLOGIES

2.1        Geometrical modelling and characterization

2.1.1     Geometrical modelling of dot-by-dot WAAM parts

2.1.2     Geometrical characterization of dot-by-dot WAAM parts

2.2        Thermo-mechanical simulation

2.3        Monitoring solutions

2.4        Microstructure-Mechanical modelling and characterization

2.5        Mechanical-Structural modelling and characterization

2.5.1     General considerations

2.5.2     Methods for mechanical characterization of dot-by-dot elements subjected to tension, compression, bending.

2.5.3     Methods for Finite Element Analyses of dot-by-dot elements subjected to different loading conditions

2.5.4     Methods for structural modelling of dot-by-dot unit cells.

2.5.5     Design of the lattice corner CSB (final demostrator).

2.5.6     LCA methods for sustainability assessment

3.     REQUIREMENTS

3.1        Dot-by-dot bars

3.1.1     Manufacturing

3.1.2     Products

3.2        Manufacturing

3.3        Geometrical modelling and characterization

3.4        Thermo-mechanical simulation

3.5        Monitoring solutions

3.6        Microstructure-Mechanical modelling and characterization

3.7        Mechanical-Structural modelling and characterization