
An integrated approach to Topology Optimization for Wire Arc Additive Manufacturing of steel components
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Wire Arc Additive Manufacturing (WAAM) is a manufacturing technique that has advantages in terms of productivity, layout and scale for metal structures. WAAM delivers great freedom and flexibility to what can be printed, which fits well with Topology Optimization (TO), specially with its complex geometries. TO offers a sustainable and cost-effective design approach by determining the optimal structural configuration through efficient material distribution. Similarly, WAAM enables precise material deposition, applying material only where necessary to maximize efficiency. Nevertheless, the integration of those procedures is not straightforward. TO may result in irregular geometries with sharp edges, overhangs or limited thickness which hinders the fabrication and increase the likelihood of defects. Further, the manufacturing parameters, such as welding specifications and path planning, influence the mechanical properties and final geometry. All these conditions collectively contribute to difficulties in direct implementation in an industrial setup. In this research, a novel approach is presented to optimize the whole process considering the peculiarities of TO and WAAM. This approach integrates the Topology Optimization, Slicing and Path Planning in a single unit, avoiding the need of Re-engineering and iterations between steps. Instead of having a different software for each step, a unique algorithm blends all stages considering the influence of each step into the others. Each step can impose conditions and restrictions to adjust the geometry, resulting in a “ready to print” component with associated weld bead strategy and mechanical properties. The technique takes a standard optimization case study to demonstrate its efficiency and practicability. The geometry is inserted as a set of ordered coordinates and a G-code file is outputted including precise weld beads and specific printing parameters, which is ready for manufacturing with accurate dimensions and suitable strength. Furthermore, the component undergoes experimental tests to acquire material properties and mechanical behaviour, validating the entire procedure.