Extending wire-arc directed energy deposition using non-gravity aligned (NGA) torch methods

McNeil, J. Logan [Mechanical, Aerospace, and Biomedical Engineering (MABE) Department, Knoxville, TN (United States)] (ORCID:0000000284124531); Penney, Joshua J. [Mechanical, Aerospace, and Biomedical Engineering (MABE) Department, Knoxville, TN (United States)] (ORCID:0000000189389734); Lamsey, Matthew [Mechanical, Aerospace, and Biomedical Engineering (MABE) Department, Knoxville, TN (United States)] (ORCID:0000000173832092); Hamel, William R. [Mechanical, Aerospace, and Biomedical Engineering (MABE) Department, Knoxville, TN (United States)] (ORCID:0000000185510058); Sebok, Michael [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)] (ORCID:000000020655195X); Thapliyal, Saket [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)] (ORCID:0000000162415904); Meyer, Luke [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)] (ORCID:0000000242172076); Noakes, Mark [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)]; Nycz, Andrzej [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)] (ORCID:0000000174156559)

doi:10.1016/j.jmapro.2025.07.062

DOE OSTI · 2584535

Extending wire-arc directed energy deposition using non-gravity aligned (NGA) torch methods

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Abstract

For standard Additive Manufacturing (AM) processes, traditional path planning typically relies on a 2.5-dimensional approach. In wire-arc directed energy deposition (DED), commonly referred to as wire-arc additive manufacturing (WAAM), this 2.5D approach inherently limits final near net shape due to the stair-step effect and restricts the maximum overhang angle achievable without part degradation. To achieve better near net shape and part quality, a 3D planning approach that modulates the tool tip position and angle without process changes is demonstrated in components containing up to 105° of unsupported overhang. The experimental methods are validated with half and fully enclosed cylinder sections containing 90° of overhang. The non-gravity aligned methods are then applied to a commercial WAAM system for a composite tool mold demonstrator part. As a result, the methods developed in this paper enable expansion of WAAM system capabilities to parts containing large overhangs without compromising the net shape or material structure of the resulting parts and without the need for a part positioner.

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McNeil, J. Logan [Mechanical, Aerospace, and Biomedical Engineering (MABE) Department, Knoxville, TN (United States)] (ORCID:0000000284124531), Penney, Joshua J. [Mechanical, Aerospace, and Biomedical Engineering (MABE) Department, Knoxville, TN (United States)] (ORCID:0000000189389734), Lamsey, Matthew [Mechanical, Aerospace, and Biomedical Engineering (MABE) Department, Knoxville, TN (United States)] (ORCID:0000000173832092), Hamel, William R. [Mechanical, Aerospace, and Biomedical Engineering (MABE) Department, Knoxville, TN (United States)] (ORCID:0000000185510058), Sebok, Michael [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)] (ORCID:000000020655195X), Thapliyal, Saket [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)] (ORCID:0000000162415904), Meyer, Luke [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)] (ORCID:0000000242172076), Noakes, Mark [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)], Nycz, Andrzej [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)] (ORCID:0000000174156559). 2025-08-06. Extending wire-arc directed energy deposition using non-gravity aligned (NGA) torch methods. https://doi.org/10.1016/j.jmapro.2025.07.062

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