Grebner, Philipp ; Riegraf, Lars ; Ojeda, Juan Eduardo ; Lange, Jörg
Hrsg.: Swedish Institute of Steel Construction (2024)
Reinforcing thin sheet metal using Wire Arc Additive Manufacturing: for application in free-form façade construction.
15th Nordic Steel Construction Conference (NSCC 2024). Lulea, Schweden (26.06.2024 - 28.06.2024)
doi: 10.5281/zenodo.11453894
Konferenzveröffentlichung, Bibliographie

Kurzbeschreibung (Abstract)

Additive manufacturing with steel wire, also known as Wire Arc Additive Manufacturing (WAAM), has become increasingly important in structural engineering research in past years. WAAM enables the layer-by-layer construction of steel structures, considering the load path, so that it enables significant material savings compared to subtractive manufacturing methods. To date, free-form sheet metal façades can only be realized using large sheet metal thicknesses, inducing high dead weights, and resulting in high material consumptions and costs. The use of WAAM to reinforce thin sheets for façade construction could offer a more ecological and economical solution. Within a research project at the TU Darmstadt, a WAAM reinforced demonstrator with a sheet thickness of 1.0 mm was developed for a rear-ventilated façade construction. Thereby, applicable welding process parameters were developed, allowing a layer-by-layer build-up of weld seams, without melting through the sheet metal. The weld metal was tested for sufficient ductility and strength in tensile tests considering the influence of active cooling on the material properties. Using a depth camera, the coordinates for the welding path were captured and automatically converted into a robot code. Alongside the material properties of the weld metal, the weld-induced deformation of the sheet metal plays a decisive role. Within a parameter study, the uniaxial weld-induced deformation of sheet metal strips measuring 200 x 1000 cm was quantified both experimentally and numerically in relation to the weld layer height. The experimental study was carried out on flat and elastically pre-curved sheets using a frame with a radius of 5 m. Working with a depth camera, the coordinates for the welding path were captured and automatically converted into the robot code. A statistical model was used to investigate whether the curvature of the sheet metal strips can be represented by a parabolic or circular function.

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