Simulation-based process planning of the WAAM process (SimPro WAAM)

• Applicants: Professor Dr.-Ing. Berend Denkena; Dr.-Ing. Thomas Hassel
• Subject Area: Primary Shaping and Reshaping Technology, Additive Manufacturing ; Joining and Separation Technology
• Term: since 2025
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 556856929

Additive manufacturing is increasingly being used in series production. Due to its high deposition rates and the possibility of welding structures onto semi-finished products, wire and arc additive manufacturing (WAAM) offers great potential for the production of medium and large components in small and medium series. The great potential, of unit costs independent of the volume, cannot be accessed due to the incomplete digital process chain of the WAAM process. Currently, the determination of the optimal process parameters is done experimentally. In order to make customerspecific products and small batches feasible, the process chain must be completely digitized. Therefore, the experimental pre-tests have to be replaced by a process simulation. This application lays the foundation to fully simulate the WAAM process and to be able to plan a simulation-based process in perspective. A multiscale process model for the simulation of additive manufactured workpiece geometries will be researched using the MIG/MAG WAAM process as an example. In order to achieve fast simulation on the one hand and accurate prediction on the other hand, the process is investigated in two different dimensions. On the microscale, the resulting weld geometry is investigated by the influence of the relevant process parameters and boundary conditions on the critical material properties. On the macro scale, the joining of the individual weld segments from the micro model to a complete component is investigated, in addition the macro model maps the temperature profile of the component and gives the boundary conditions/input variables (interpass temperature, path planning, substrate geometry, ...) to the micro model. In this research project, three different reference geometries made of steel are investigated. Finally, the accuracy of the workpiece prediction will be determined on a component consisting of the different reference geometries. Finally, the transferability of the model approach to other materials is investigated on the basis of aluminum.

• DFG Programme: Research Grants