Wire Arc Additive Manufacturing of Complex-Shaped Capsules for HIP Sintering of Powder

Abstract

Featured Application: A new hybrid process for prototyping medium-size metal components with enhanced mechanical properties, especially within the framework of the nuclear industry. This work focuses on wire arc additive manufacturing for the rapid prototyping of shell-type parts such as sealed containers/capsules required in the manufacturing of metal components using hot isostatic pressing (HIP) of powder. The selected material was AISI 316L. The automatic generation step of robot trajectories from the CAD design of the part to be manufactured was addressed first. The mechanical and metallurgical properties of WAAM samples were then evaluated. Finally, a hollow cylindrical capsule manufactured by WAAM was used for the HIP sintering of powder to demonstrate the relevance of the hybrid technology. The main results are as follows: 1. The Ultimate Tensile Strength (UTS) of AISI 316L WAAM samples was measured be-19 tween 540 MPa (longitudinal direction) and 600 MPa (transverse direction). 2. The as-manufactured WAAM parts present a residual (δ) ferrite content of 5–7%. 3. HIP processing permitted to reset a fully austenitic structure within the WAAM wall/shell. 4. The grain size was found to be coarser in the WAAM walls and finer in the core of the part (made of sintered powder). Finally, the suggested hybrid process may become an alternative technology for the manufacture of medium-size metal components in the nuclear industry.