TY - GEN A1 - Israr, Rameez A1 - Buhl, Johannes A1 - Bambach, Markus T1 - A study on power-controlled wire-arc additive manufacturing using a data-driven surrogate model T2 - The International Journal of Advanced Manufacturing Technology N2 - Wire-arc additive manufacturing (WAAM) provides an alternative for the production of various metal products needed in medium to large batch sizes due to its high deposition rates. However, the cyclic heat input in WAAM may cause local overheating. To avoid adverse effects on the performance of the part, interlayer dwelling and active cooling are used, but these measures increase the process time. Alternatively, the temperature during the WAAM process could be controlled by optimizing the welding power. The present work aims at introducing and implementing a novel temperature management approach by adjusting the weld-bead cross-section along with the welding power to reduce the heat accumulation in the WAAM process. The temperature evolution during welding of weld beads of different cross-sections is investigated and a database of the relation between optimal welding power for beads of various sizes and different pre-heating temperatures was established. The numerical results are validated experimentally with a block-shaped geometry. The results show that by the proposed method, the test shape made was welded with lower energy consumption and process time as compared to conventional constant-power WAAM. The proposed approach efficiently manages the thermal input and reduces the need for pausing the process. Hence, the defects related to heat accumulation might be reduced, and the process efficiency increased. Y1 - 2021 U6 - https://doi.org/10.1007/s00170-021-07358-y SN - 1433-3015 SN - 0268-3768 VL - 177 IS - 7-8 SP - 2133 EP - 2147 ER - TY - CHAP A1 - Israr, Rameez A1 - Buhl, Johannes ED - Khan, Wasim Ahmed T1 - An Introduction to Additive Manufacturing (AM) of Metals and Its Trends in Wire-Arc Additive Manufacturing (WAAM) Simulations T2 - Machine Tools : An Industry 4.0 Perspective Y1 - 2023 U6 - https://doi.org/10.1201/9781003220985 PB - CRC Press CY - Boca Raton ER - TY - GEN A1 - Israr, Rameez A1 - Buhl, Johannes A1 - Härtel, Sebastian A1 - Bambach, Markus T1 - Reinforcement of Tooling Using Residual Stresses Generated by Cladding by Arc Welding T2 - Metals N2 - Cladding is typically used to protect components from wear and corrosion while also improving the aesthetic value and reliability of the substrate. The cladding process induces significant residual stresses due to the temperature difference between the substrate and the clad layer. However, these residual stresses could be effectively utilized by modifying processes and geometrical parameters. This paper introduces a novel methodology for using the weld-cladding process as a cost-effective alternative to various existing reinforcement techniques. The numerical analyses are performed to maximize the reinforcement of a cylindrical tool. The investigation of how the weld cladding develops compressive stresses on the specimen in response to a change in the weld beads and the welding sequence is presented. For the benchmark shape, experimental verification of the numerical model is performed. The influence of the distance between the weld beads and the effect of the tool diameter is numerically investigated. Furthermore, the variation in compressive stresses due to temperature fluctuations during the extrusion process has been evaluated. The results showed that adequate compressive stresses are generated on the welded parts through the cladding process after cooling. More compressive stresses are induced in the tool as the cross-section of the weld bead is increased. Furthermore, keeping a gap between the adjacent beads improves tool reinforcement. Hence, the targeted reinforcement of the substrate can be achieved by optimizing the welding sequence and process parameters. KW - Additive Manufacturing (AM) KW - Wire Arc Additive Manufacturing (WAAM) KW - weld cladding KW - residual stresses KW - reinforcement KW - hole drilling method KW - LS-Dyna KW - numerical simulation Y1 - 2022 U6 - https://doi.org/10.3390/met12060984 SN - 2075-4701 VL - 12 IS - 6 ER - TY - GEN A1 - Sefidi, Moein Pakdel A1 - Israr, Rameez A1 - Buhl, Johannes A1 - Bambach, Markus ED - Bambach, Markus T1 - Rule-Based Path Identification for Direct Energy Deposition T2 - Procedia Manufacturing; Part of Special issue: 23rd International Conference on Material Forming Y1 - 2020 U6 - https://doi.org/10.1016/jpromfg.2020.04.133 SN - 2351-9789 VL - 47 SP - 1134 EP - 1140 ER - TY - GEN A1 - Buhl, Johannes A1 - Klöppel, Thomas A1 - Merten, Mathias A1 - Haufe, Andre A1 - Israr, Rameez A1 - Bambach, Markus T1 - Numerical prediction of process-dependent properties of high-performance Ti6Al4 in LS-DYNA T2 - ESAFORM 2021 : 24th International Conference on Material Forming Y1 - 2021 U6 - https://doi.org/doi: 10.25518/esaform21.1496 ER - TY - GEN A1 - Nguyen, Lam A1 - Buhl, Johannes A1 - Israr, Rameez A1 - Bambach, Markus T1 - Analysis and compensation of shrinkage and distortion in wire-arc additive manufacturing of thin-walled curved hollow sections T2 - Additive Manufacturing Y1 - 2021 U6 - https://doi.org/10.1016/j.addma.2021.102365 SN - 2214-8604 VL - Vol. 47 ER - TY - GEN A1 - Israr, Rameez A1 - Buhl, Johannes A1 - Bambach, Markus ED - Bambach, Markus T1 - Numerical Analysis of Different Fixation Strategies in Direct Energy Deposition Processes T2 - Procedia Manufacturing; Part of Special issue: 23rd International Conference on Material Forming; edited by Markus Bambach Y1 - 2020 U6 - https://doi.org/10.1016/j.promfg.2020.04.145 SN - 2351-9789 VL - 47 SP - 1184 EP - 1189 ER - TY - GEN A1 - Buhl, Johannes A1 - Israr, Rameez A1 - Bambach, Markus T1 - Modeling and convergence analysis of directed energy deposition simulations with hybrid implicit / explicit and implicit solutions T2 - Journal of Machine Engineering Y1 - 2019 U6 - https://doi.org/10.5604/01.3001.0013.4086 SN - 2391-8071 SN - 1895-7595 VL - Vol. 19 IS - 3 SP - 94 EP - 107 ER - TY - CHAP A1 - Beisegel, Jesse A1 - Buhl, Johannes A1 - Israr, Rameez A1 - Schmidt, Johannes A1 - Bambach, Martin A1 - Fügenschuh, Armin ED - Cristiani, Emiliano ED - Falcone, Maurizio ED - Tozza, Silvia T1 - Mixed-Integer Programming Models for Two Metal Additive Manufacturing Methods T2 - Mathematical Methods for Objects Reconstruction Y1 - 2023 SN - 978-981-9907-75-5 SN - 978-981-9907-76-2 SP - 121 EP - 155 PB - Springer CY - Heidelberg ER -