Material-informed topology optimization for Wire-and-Arc Additive Manufacturing

Abstract

Wire-and-Arc Additive Manufacturing (WAAM) is a metal 3d printing technique that allows fabricating elements ranging from simple geometry to extremely complex shapes. “Layer-by-layer” manufacturing produces a printed material with significant elastic anisotropy, whereas “dot-by-dot” printing may be used to fabricate funicular geometries in which the mechanical properties of the single bars are affected by the printing process. The design of WAAM components is addressed by formulating problems of structural optimizations that account for the peculiar features of the printed alloy. Topology optimization by distribution of anisotropic material is exploited to find optimal shapes in layer-by-layer manufacturing. Two-dimensional specimens are addressed along with I-beams. In the latter case it is assumed that a web plate and two flanges are printed and subsequently welded to assemble the structural component. A constrained force density method is proposed for the design of grid shells in dot-by-dot printing, formulating local enforcements to govern the magnitude of the axial force in each branch of the network. In both formulations, the arising multi-constrained problem is efficiently tackled through methods of sequential convex programming. Lightweight solutions for layer-by-layer and dot-by-dot manufacturing are found for given printing directions. Extensions of the proposed numerical tools are highlighted to endow the optimization problems with additional set of material-related constraints.