Augmenting wire arc additive manufacturing with laser forming for generative realization of complex geometries

Due to its advantages like higher deposition rates and lower costs, Wire Arc Additive Manufacturing (WAAM) is increasingly used to fabricate metal AM parts, particularly big-sized components. However, realization of complex geometrical features, like overhangs, remains one of the major challenges. The present work describes a hybrid approach of intervention of fiber laser intermittently during part fabrication to enhance the geometrical complexity possible. In this two-step process, a component deposited in first stage is subjected to multiple laser passes in second stage to obtain a desired angle/shape. This cycle of deposition and laser forming continues till the final desired geometry is realized. The study includes preliminary trials on deposited specimens to understand dominant laser bending mechanism and decide optimum laser process parameters. Subsequently, a few illustrative components are manufactured using current hybrid process, establishing the effectiveness of this approach in realizing complex shapes, thus laying a foundation for a potential metal 4D printing technology.