TY - THES

T1 - Impact of the Wire Arc Additive Manufacturing (WAAM) process on the distortion and residual stress state of rapidly rotating components in solid/liquid separation

AU - Ruess, Leon

N1 - embargoed until 02-02-2029

PY - 2024

Y1 - 2024

N2 - Wire as a feedstock referred to as Wire Arc Additive Manufacturing for Additive Manufacturing purposes has been investigated since the 1990s. The advantages of WAAM mainly are the high deposition rates, the freedom of geometry with a high dimensional accuracy and potentially low delivery times. Due to these facts, WAAM is gaining technical and economic relevance, but needs to be investigated to benefit to its advantages in comparison to conventional component manufacturing. Based on the inevitable heat input during WAAM, the knowledge of the impact on the distortion and residual stress state is essential. In this master thesis, this impact of a WAAMed flange on a decanter centrifuge¿s cylindrical bowl out of 1.4362 and 1.4462 is investigated by destructive and non-destructive measurements. In addition, mechanical properties and the microstructure of the used materials are characterized by tensile testing, hardness mappings, light optical and stereo microscope investigations. Finally, the performed WAAM process is assessed in terms of economic operation as an alternative to the conventional centrifugal casting manufacturing process. These investigations showed that the cylindrical bowl is plastically deformed in the area of the WAAMed flange and elastic deformation also occurs up to much greater distances.

AB - Wire as a feedstock referred to as Wire Arc Additive Manufacturing for Additive Manufacturing purposes has been investigated since the 1990s. The advantages of WAAM mainly are the high deposition rates, the freedom of geometry with a high dimensional accuracy and potentially low delivery times. Due to these facts, WAAM is gaining technical and economic relevance, but needs to be investigated to benefit to its advantages in comparison to conventional component manufacturing. Based on the inevitable heat input during WAAM, the knowledge of the impact on the distortion and residual stress state is essential. In this master thesis, this impact of a WAAMed flange on a decanter centrifuge¿s cylindrical bowl out of 1.4362 and 1.4462 is investigated by destructive and non-destructive measurements. In addition, mechanical properties and the microstructure of the used materials are characterized by tensile testing, hardness mappings, light optical and stereo microscope investigations. Finally, the performed WAAM process is assessed in terms of economic operation as an alternative to the conventional centrifugal casting manufacturing process. These investigations showed that the cylindrical bowl is plastically deformed in the area of the WAAMed flange and elastic deformation also occurs up to much greater distances.

KW - Wire Arc Additive Manufacturing

KW - DUPLEX Stähle

KW - Eigenspannungen

KW - Verzug

KW - Mechanische Eigenschaften

KW - Wire Arc Additive Manufacturing

KW - Duplex Stainless Steels

KW - Residual Stresses

KW - Distortion

KW - Mechanical Properties

U2 - 10.34901/mul.pub.2024.103

DO - 10.34901/mul.pub.2024.103

M3 - Master's Thesis

ER -