AKT Project with WAAM3D: Next generation high-performance MIG process for additive manufacturing

Process DevelopmentWorking at the Welding and Additive Manufacturing Centre in the area of Wire Arc Additive Manufacturing - NEWAM project (https://newam.uk/). At the forefront of the development of the CWGMA AM (Cold Wire Gas Metal Arc Additive Manufacturing) process.Metal additive manufacturing, particularly Wire Arc Additive Manufacturing (WAAM), offers significant advantages compared to traditional technologies regarding lead times, material savings and overall costs. Development of an innovative process and respective control methods to increase productivity even further while accurately managing energy input and bead geometry.• Achieved 15.95 kg/h in experimental studies and 9.57 kg/h at a demonstrator part.• Increased process efficiency up to 73.5 %.• Contributed to the patent application GB2601784.• Designed a torch end effector customised for CWGMA, procured the raw material and manufacturing facility, and installed and tested the prototype. • Aided teaching experimental classes of Welding Engineering and Metal Additive Manufacturing courses and trained Master students on how to operate WAAM equipment.• Have numerous suggestions for future work and development in WAAM.

The LASIMM (Large Additive/Subtractive Integrated Modular Machine) Project - http://www.lasimm.eu/index.html Non-Destructive Testing and Quality ManagementParts manufactured using a state-of-art technology, in this case Wire Arc Additive Manufacturing (WAAM), require a continuous improvement in its quality. Study of the most common defects and issues related with the production process. Development of a testing method and respective sensors to control and assure in real time the quality of the manufactured parts.• Creation and implementation of sensors capable of detecting flawed parts during production, hence allowing an inline repair of the defect.• Draft functional objects and use the fast prototyping capabilities of 3D polymeric printing to assist in the design phase of products.• Production of small demonstrator parts using WAAM.• Autodesk PowerMill + Robot + Additive Training. • Presented my work to highly reputable audiences in project meetings in a few European countries.• Writing of scientific articles to publish in expertise journals.• Aided to redact teaching material for an European Master Degree.