T-GMAW based novel Multi-node trajectory planning for fabricating grid stiffened panels: An efficient production technology

Through this decade of research, wire arc additive manufacturing (WAAM) has the potential and feasibility to fabricate large aerospace aluminum alloy components that feature high intensity and buy-to-fly ratio with appropriate heat treatment and post machining. However, few studies have been carried out specifically for medium and larger grid structural panels using higher efficiency WAAM. This paper presents an innovative Multi-node trajectory planning strategy combined Tandem Gas Metal Arc Welding (T-GMAW) process to realize efficiently fabrication. The applied T-GMAW process is able to deposit a large width bead more than 12 mm once, the novel trajectory planning algorithm and strategy can generate a continuous forming path of Multi-node and Multi trajectory which grid stiffened panels contain a lot. The combination of the two methods succeeds in realizing WAAM of the grid structure and significantly reduce production time, energy and material waster, while simultaneously minimizing the number of interruptions. The procedure and theory of trajectory planning were described and validated through conducting the experiments for various grid panels with the widely used aluminum alloy 2219. As a result, the arc arcing and extinguishing points was greatly reduced with the increase of grid-scale than other path planning method. Several aspects over traditional machining methods were analyzed, such as the main energy consumption was reduced from 73.5 kW to 4 kW, the time consumption was reduced average 33.4% per unit grid, the facility cost reduces about 90%, the material removal volume reduced more than 95%. Therefore, this production method would not only improve the forming efficiency but also promote the WAAM commercial application.