3D metal printing with Wire Arc Additive Manufacturing (WAAM) is being used in an increasing number of applications. GEFERTEC, a pioneer in this area, is now expanding the range of available machines with its new arc80X series. This latest generation of machines is in response to widespread customer demand for the ability to produce larger parts with WAAM.
Credit: GEFERTEC GmbH
Larger assembly space and more automation
For the machine’s kinematics, GEFERTEC relies upon a CNC-controlled linear axis system, whose high precision ensures sustained process stability and repeatability throughout the entire assembly space. In the 3-axis version, the new production system has an assembly space of 2 x 2 x 2 m and can produce parts with a total mass of up to eight tons. The 5-axis version prints parts with a diameter of up to 0.9 m and a height of up to 1.4 m. In addition to the larger assembly space, this new generation of machines offers many other advantages. These include a higher degree of automation to improve production efficiency and reduce personnel requirements. Automated functions include integrated tool measurement, gas nozzle cleaning, wire cutting, and replacement of wear parts.
The new machine generation also scores points with refined process monitoring to ensure part quality. The process monitor records and stores all relevant data during the printing process. This allows comprehensive documentation for quality assurance and process optimization. An integrated pyrometer measures the part temperature and, together with active component cooling, contributes to optimal quality of the printed part. The optional inert gas box enables printing in a closed inert gas atmosphere. This allows the unit to process even sensitive materials such as titanium.
Process know-how as a service offering
In the past, many potential users of the innovative 3D printing process were reluctant to invest in their own machines. In many cases, this was primarily due to a lack of expertise within the company. GEFERTEC will also be offering a comprehensive service package for this in the future. With their extensive know-how, GEFERTEC process technicians and CAM engineers support customers in easily changing over their parts manufacturing process to the arc machines. Services include parts screening to review technical feasibility and to identify potential areas of increased efficiency. The GEFERTEC experts can also help in the qualification processes. This allows customers to make optimal use of the arc machine and start 3D printing with WAAM even without inhouse experts.
Proven machine design
GEFERTEC has retained the advantages of the previous machine generation in the new arc80X series. The machine is designed as a complete production system based upon the WAAM process. Traditional metal inert gas welding is used for the additive manufacturing of parts. The arc machines combine this with special CAM software and a Sinumerik control architecture. The process offers high build rates, and because wire is used as the raw material, handling is easy and the material is cost-effective. The machines are already being used extensively in industrial applications, such as mass production of turbine components in the energy sector.