Hybridization in Metal Wire Additive Manufacturing: A Case Study of an Impeller
Additive manufacturing (AM) has evolved to enable the direct production of functional components through the hybridization of additive and subtractive processes. In metal wire AM, hybridization is key, encompassing process integration (addition/subtraction), energy source combinations (arc/laser), k...
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| Format: | Article |
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MDPI AG
2025-01-01
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| Series: | Metals |
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| Online Access: | https://www.mdpi.com/2075-4701/15/1/71 |
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| author | Shahu R. Karade Siddhartha Siddhartha Neel Kamal Gupta Ganesan G K. P. Karunakaran Henning Zeidler |
| author_facet | Shahu R. Karade Siddhartha Siddhartha Neel Kamal Gupta Ganesan G K. P. Karunakaran Henning Zeidler |
| author_sort | Shahu R. Karade |
| collection | DOAJ |
| description | Additive manufacturing (AM) has evolved to enable the direct production of functional components through the hybridization of additive and subtractive processes. In metal wire AM, hybridization is key, encompassing process integration (addition/subtraction), energy source combinations (arc/laser), kinematic options (3/4/5 axis), and slicing techniques (planar/conformal). This paper focuses on these hybridization methods, with a unified system designed for single-machine setups, improving efficiency and accuracy. This study presents a detailed exploration of these hybridization levels through the fabrication of a complex 5-axis geometry—an impeller. The impeller was manufactured with hybridization using various levels and subsequently compared with manufacturing processes like additive manufacturing with interlayer machining and traditional machining methods. The hybrid approach significantly reduced the manufacturing time for the selected impeller geometry from 3536 min to 792 min (saving 77.6% manufacturing time) and minimized material waste to 9.3%, compared with 74.07% in traditional machining. This demonstrates a more efficient, precise, and cost-effective method to optimize metal wire AM for producing complex metal components, advancing capabilities and applications. |
| format | Article |
| id | doaj-art-0c7619317fec4fbd8c51158af9fc8d07 |
| institution | Kabale University |
| issn | 2075-4701 |
| language | English |
| publishDate | 2025-01-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Metals |
| spelling | doaj-art-0c7619317fec4fbd8c51158af9fc8d072025-01-24T13:41:35ZengMDPI AGMetals2075-47012025-01-011517110.3390/met15010071Hybridization in Metal Wire Additive Manufacturing: A Case Study of an ImpellerShahu R. Karade0Siddhartha Siddhartha1Neel Kamal Gupta2Ganesan G3K. P. Karunakaran4Henning Zeidler5Department of Mechanical Engineering, Indian Institute of Technology Bombay, Powai, Mumbai 400076, IndiaDepartment of Mechanical Engineering, Indian Institute of Technology Bombay, Powai, Mumbai 400076, IndiaInstitute for Machine Elements, Engineering Design and Manufacturing (IMKF), Technische Universität Bergakademie Freiberg, 09599 Freiberg, GermanyDepartment of Metallurgical Engineering and Materials Science, Indian Institute of Technology Bombay, Powai, Mumbai 400076, IndiaDepartment of Mechanical Engineering, Indian Institute of Technology Bombay, Powai, Mumbai 400076, IndiaInstitute for Machine Elements, Engineering Design and Manufacturing (IMKF), Technische Universität Bergakademie Freiberg, 09599 Freiberg, GermanyAdditive manufacturing (AM) has evolved to enable the direct production of functional components through the hybridization of additive and subtractive processes. In metal wire AM, hybridization is key, encompassing process integration (addition/subtraction), energy source combinations (arc/laser), kinematic options (3/4/5 axis), and slicing techniques (planar/conformal). This paper focuses on these hybridization methods, with a unified system designed for single-machine setups, improving efficiency and accuracy. This study presents a detailed exploration of these hybridization levels through the fabrication of a complex 5-axis geometry—an impeller. The impeller was manufactured with hybridization using various levels and subsequently compared with manufacturing processes like additive manufacturing with interlayer machining and traditional machining methods. The hybrid approach significantly reduced the manufacturing time for the selected impeller geometry from 3536 min to 792 min (saving 77.6% manufacturing time) and minimized material waste to 9.3%, compared with 74.07% in traditional machining. This demonstrates a more efficient, precise, and cost-effective method to optimize metal wire AM for producing complex metal components, advancing capabilities and applications.https://www.mdpi.com/2075-4701/15/1/71additive manufacturingdirected energy depositionhybrid layered manufacturinglaser wire claddingmulti-axis depositionwire arc additive manufacturing |
| spellingShingle | Shahu R. Karade Siddhartha Siddhartha Neel Kamal Gupta Ganesan G K. P. Karunakaran Henning Zeidler Hybridization in Metal Wire Additive Manufacturing: A Case Study of an Impeller Metals additive manufacturing directed energy deposition hybrid layered manufacturing laser wire cladding multi-axis deposition wire arc additive manufacturing |
| title | Hybridization in Metal Wire Additive Manufacturing: A Case Study of an Impeller |
| title_full | Hybridization in Metal Wire Additive Manufacturing: A Case Study of an Impeller |
| title_fullStr | Hybridization in Metal Wire Additive Manufacturing: A Case Study of an Impeller |
| title_full_unstemmed | Hybridization in Metal Wire Additive Manufacturing: A Case Study of an Impeller |
| title_short | Hybridization in Metal Wire Additive Manufacturing: A Case Study of an Impeller |
| title_sort | hybridization in metal wire additive manufacturing a case study of an impeller |
| topic | additive manufacturing directed energy deposition hybrid layered manufacturing laser wire cladding multi-axis deposition wire arc additive manufacturing |
| url | https://www.mdpi.com/2075-4701/15/1/71 |
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