PROCESS
LIBRARY

Metalworm offers suitable material qualities produced using the WAAM process.

Metalworm gives you the ability to create high-quality geometries with less tolerance from the CAD model thanks to integrated process parameter libraries in the system for each material.

A thorough parametric study of the WAAM process served as the foundation for the process library, which now includes process parameters for aluminum and steel alloys.

Choose your material, then have fun printing your component!

Wire Arc Additive Manufacturing, Direct Energy Deposition, WAAM, DED

“Choose materIals that have the structural potentIal to sustaIn and bear the buIldIng loads”

MetalWorm can be used to build parts utilizing a variety of metals and alloys. A few materials have been used, and the relevant mechanical properties have been shared in the process library. MetalWorm team is investigating additional materials and will soon release the process specifications for those materials.

Our approach and integrated technologies at MetalWorm are particularly adaptable to practically any material, which results in excellent mechanical qualities of WAAM manufactured components.

In general, and from the perspective of mechanics, a good material is one that has

Homogeneous microstructure

Isotropic mechanical characteristics

No microstructural defects such as porosity

WAAM RT

The materIals utIlIzed so far by MetalWorm's WAAM method have acceptable and IsotropIc mechanIcal propertIes, homogeneous mIcrostructure, and nearly no porosIty.

MATERIALS

ALUMINUM ALLOYS

2319, 4043, 5183, 5356, 5087, 6063

STEEL ALLOYS

ER70, ER80, ER90, ER120

STAINLESS STEEL

316L, 304L, Duplex, Invar

TITANIUM GRADES

Ti6Al4V Grade 5

INCONEL ALLOYS

Inconel 625, Inconel 718

ACTIVE COOLING TECHNOLOGY

High heat accumulation in WAAM have a negative effect on the stability of the process in terms of the geometrical accuracy, deposition defects, microstructural evolution and material properties of as-fabricated parts. A common way of preventing heat accumulation is to implement interlayer cooling times before depositing the subsequent layer. However, the idle times required to cool down the interlayer temperature during printing of large scale components can be significantly high which is against the higher deposition rate nature of the WAAM process.

 

Metal Worm suggests a brand-new active cooling system that promotes heat transmission to the substrate and thus reduce high heat accumulation. Additionally, active cooling technology makes it possible to produce parts on thinner substrates, which reduces substrate waste and costs.

 

The WAAM process can be accelerated using active cooling technology by cutting down on the inter-layer cooling time.

MetalWorm’s studies has revealed that the presence of cooling table in WAAM process slightly decreases the grain size and has nearly no effect on the phase distribution.

MetalWorm Cooling Table + Wire Arc AM

Wire Arc AM

VIBRATION TECHNOLOGY

Coarse and columnar grains, such as dendritic structure, are generated in the microstructure as a result of the cyclic and rapid heating and cooling that occurs during the Wire + Arc Additive Manufacturing (WAAM) processing of materials. Implementing in-situ vibration prevents the development of columnar grains and encourages the transition of coarse columnar grains into fine and equiaxed grains, leading to superior mechanical characteristics. Vibration assisted WAAM process can also reduce residual stresses, subsequent and eventually increases the accuracy of the geometry.

 

It was observed that the elongation of the columnar grains formed in the interface of substrate and WAAM fabricated part decreases when the vibration table was incorporated during the process. It is then predicted that implementing ultrasonic vibration can further refine the microstructure and achieve equiaxed grains in WAAM process.

MetalWorm Vibration Table + Wire Arc AM

Wire Arc AM

WAAM Part, DED Part, Steel Part, Metal Additive Manufacturing, WAAM Oil and Gas

OIL AND GAS

ER70S-6 Steel Alloy

Size Ø435x300mm
Weight 51.39kg
Print Time 48h 20m

WAAM Part, DED Part, Invar 36 Part, Metal Additive Manufacturing, WAAM Dome Shape Mold Part, Aerospace Mold Part

DOME SHAPE MOLD PART

Invar 36

Size Ø400x100mm
Weight 35.5kg
Print Time 18h 24m

WAAM Part, DED Part, Stainless Steel Part, Metal Additive Manufacturing, WAAM Propeller

PROPELLER

ER316LSi Stainless Steel​

Size Ø380X80mm
Weight 3.8kg
Print Time 11h 57m

WAAM Part, DED Part, Steel Part, Metal Additive Manufacturing, WAAM Blisk

BLISK

ER70S-6 Steel Alloy

Size 220x220x105mm
Weight 9kg
Print Time 3h 12m

WAAM Part, DED Part, Steel Part, Metal Additive Manufacturing, WAAM Cylinder

CYLINDER WALL

ER70S-6 Steel Alloy

Size Ø135x80mm
Weight 2.3kg
Print Time 3h 55m

WAAM Part, DED Part, Steel Part, Metal Additive Manufacturing, WAAM Airfoil, Aerospace

AIRFOIL

ER5356 Aluminum Alloy

Size 250x100x200mm
Weight 1.46kg
Print Time 1h 46m

WAAM Part, DED Part, Steel Part, Metal Additive Manufacturing

ART MODEL

ER70S-6 Steel Alloy

Size 220x220x200mm
Weight 6.4kg
Print Time 5h 33m

WAAM Part, DED Part, Steel Part, Metal Additive Manufacturing

TWO-AXIS POSITIONER PART

ER70S-6 Steel Alloy

Size Ø150x130mm
Weight 7.9kg
Print Time 9h 9m

WAAM Part, DED Part, Steel Part, Metal Additive Manufacturing, WAAM Landing Gear, Aerospace

LANDING GEAR PART

ER70S-6 Steel Alloy

Size 300x300x100mm
Weight 11.8kg
Print Time 12h 43m

WAAM Part, DED Part, Steel Part, Metal Additive Manufacturing, WAAM Aluminium Art Part

ART PART

ER5356 Aluminum Alloy

Size 160x100x505mm
Weight 3.9kg
Print Time 5h 30m

WAAM Part, DED Part, Steel Part, Metal Additive Manufacturing, WAAM HEXAGON LOFTED TO CIRCLE PROFIL ER5356 Aluminum Alloy

HEXAGON LOFTED TO CIRCLE PROFIL

ER5356 Aluminum Alloy

Size 140x120x190mm
Weight 1.88kg
Print Time 2h 16m

WAAM Part, DED Part, Steel Part, Metal Additive Manufacturing, WAAM SPIRAL VORTEX CUBE ER5356 Aluminum Alloy

SPIRAL VORTEX CUBE MODEL

ER5356 Aluminum Alloy

Size 150x150x170mm
Weight 1kg
Print Time 1h 14m

WAAM Part, DED Part, Steel Part, Metal Additive Manufacturing, WAAM HUGGING MODEL ER5356 Aluminum Alloy

HUGGING MODEL

ER5356 Aluminum Alloy

Size 200x170x280mm
Weight 1.57kg
Print Time 1h 54m

THREE LEG MODEL

ER5356 Aluminum Alloy

Size 400x400x360mm
Weight 3.24kg
Print Time 3h 55m

WAAM Part, DED Part, Steel Part, Metal Additive Manufacturing, Goldak Heat Source Model

GOLDAK HEAT SOURCE MODEL

ER5356 Aluminum Alloy

Size 50x150x180mm
Weight 0.8kg
Print Time 0h 57m

WAAM Part, DED Part, Steel Part, Metal Additive Manufacturing, WAAM BENT PIPE MODEL ER5356 Aluminum Alloy

BENT PIPE MODEL

ER5356 Aluminum Alloy

Size Ø85x220mm
Weight 1.64kg
Print Time 1h 59m

WAAM Part, DED Part, Steel Part, Metal Additive Manufacturing, WAAM Aluminium Organic Structure, ER4043

ORGANIC STRUCTURE

ER4043 Aluminum Alloy

Size 150x150x360mm
Weight 2.66kg
Print Time 3h 15m

WAAM Part, DED Part, Steel Part, Metal Additive Manufacturing, WAAM Rocket Nozzle, Aerospace

ROCKET NOZZLE

ER316LSi Stainless Steel

Size Ø250x400mm
Weight 14kg
Print Time 10h 59m

WAAM Part, DED Part, Steel Part, Metal Additive Manufacturing, WAAM Rotating Rectangular Stainless Steel Part

ROTATING RECTANGULAR PART

ER316LSi Stainless Steel

Size 55x105x505mm
Weight 8.3kg
Print Time 4h 55m

WAAM Part, DED Part, Steel Part, Metal Additive Manufacturing, WAAM Stainless Steel Cylinder

THIN CYLINDER WALL

ER316LSi Stainless Steel

Size Ø90x100mm
Weight 1.5kg
Print Time 2h 5m

WAAM Part, DED Part, Steel Part, Metal Additive Manufacturing, WAAM Helix

HELIX

ER70S-6 Steel Alloy

Size Ø95x275mm
Weight 1kg
Print Time 2h 27m

alt : ER70S6
alt : ER316LSi
alt : ER5356
alt : ER4043