Wire Arc Additive Manufacturing (WAAM / DED-Arc)
© Fraunhofer IAPT
Wire Arc Additive Manufacturing (WAAM / DED-Arc) auch Lichtbogen-Draht-Auftragschweißen Foto von den Anlagen am Fraunhofer IAPT

WAAM (DED-Arc)

© Fraunhofer IAPT

WAAM in Industrial Production

WAAM (DED-Arc): Additive Manufacturing and Repair of Large Components

Wire arc deposition welding, also known as Wire Arc Additive Manufacturing (WAAM / DED-Arc), enables the cost-effective production and repair of large components in high volumes. WAAM complements powder- and other wire-based 3D printing processes by offering a solution based on an established and well-known welding process that enables high deposition rates.

The DED team at Fraunhofer IAPT advises companies on the use of WAAM, assesses the challenges facing the industry, and optimizes the entire WAAM process—from process parameter development to digital methods. The expertise of the WAAM specialists at Fraunhofer IAPT enables companies—especially those with little experience—to get started with WAAM quickly and with minimal barriers to entry.

What does the industry use WAAM (DED-Arc) for?

The manufacturing and repair of large-volume components benefit greatly from WAAM (DED-Arc). In these applications, traditional powder- or wire-based 3D printing processes reach their economic or technical limits.

WAAM makes it possible to repair industrial equipment and components instead of ordering replacement parts.
© Getty Images
WAAM makes it possible to repair industrial equipment and components instead of ordering replacement parts.

The aerospace industry uses WAAM for the manufacturing and repair of engine casings and structural components.

The maritime industry and shipbuilding use WAAM, for example, to manufacture ship propellers, bushings in the propulsion system, and rudder blades.

The oil and gas industry uses WAAM to repair and manufacture turbine blades, pipe segments, drill heads, and housing components.

Using WAAM, the toolmaking department applies wear-resistant coatings to large tools or repairs damaged molds.

How does WAAM (DED-Arc) work?

WAAM (DED-Arc) is cost-effective and fast, but it requires a relatively high level of effort and extensive knowledge of production processes.

In Wire Arc Additive Manufacturing (WAAM / DED-Arc), an electric arc melts a continuously fed metal wire. Layer by layer, the molten metal is used to build the desired three-dimensional shape on a base plate or for example, in repairs or hybrid manufacturing, on an existing component.

WAAM is also known as robot-assisted deposit welding. An industrial robot or a gantry system is typically used to control the process. The welding torch is guided precisely along a predetermined path according to defined parameters. A shielding gas prevents oxidation of the molten pool and the cooling metal. 

 

Digital Assistance System Simplifies WAAM

The Fraunhofer IAPT, in collaboration with project partners, has developed a  digital assistance system using mixed-reality (XR) glasses for WAAM. It eliminates inefficient process steps and cuts the time required for WAAM production preparations in half. In addition to saving time, the assistance system helps improve the quality of WAAM components.

The help system enables companies with little prior knowledge to utilize the efficient but sophisticated WAAM 3D printing technology.

Das Fraunhofer IAPT verfügt über WAAM-Anlagen für Forschungszwecke und Industrieprojekte
© Fraunhofer IAPT
Fraunhofer IAPT has WAAM facilities for research purposes and industrial projects
Neues Assistenzsystem des Fraunhofer IAPT vereinfacht robotergestütztes Auftragschweißen (WAAM)
© Fraunhofer IAPT
An assistance system featuring mixed-reality (XR) glasses developed by Fraunhofer IAPT simplifies the use of WAAM
Wissenschaftler am Fraunhofer IAPT forschen zu WAAM
© Fraunhofer IAPT
Scientists at Fraunhofer IAPT are conducting research on WAAM

When is WAAM the appropriate DED process?

WAAM is a cost-effective and fast 3D printing process that is suitable for large components without intricate structures.

WAAM uses an electric arc as its energy source and is characterized by a very high build rate. With many other additive manufacturing processes, 3D printing of small metal parts takes hours or days. In contrast, WAAM can process several kilograms of material per hour and, as a result, produce large parts quickly.

However, the high deposition rate results in rougher surfaces. WAAM is unsuitable for complex, delicate components. 3D printing processes such as Laser Powder Bed Fusion (L-PBF) are suitable for manufacturing geometrically complex metal components.

WAAM (DED-Arc) and other DED and 3D printing technologies

The experts at Fraunhofer IAPT help companies identify the right DED technology for their project: Whether it’s WAAM, laser powder deposition (DED-LB/p), powder bed processes such as L-PBF and sinter AM, or laser wire deposition (DED-LB/w)—we ensure that you achieve optimal results.

WAAM or Laser Powder Deposition Welding

WAAM uses less expensive wire materials instead of powder materials and requires more robust, less complex equipment than laser powder deposition (DED-LB/p).

The deposition rate is significantly higher. Due to the lower level of detail, WAAM components require more extensive post-processing, such as milling. 

An Overview of DED Processes

WAAM or Powder Bed Process

With WAAM, material can be applied directly to an existing component or a base plate with non-planar surfaces. Depending on the design, the base plate can be integrated into the component as needed (e.g., a flange). Thanks to additional manipulators, there are virtually no restrictions on component size during handling. Material and equipment costs are also significantly lower.

With WAAM, the cost per kilogram produced is significantly lower than with powder-bed processes. However, the design freedom in terms of geometry and component complexity is more limited. The lower surface quality and dimensional accuracy of WAAM require more extensive post-processing than powder-bed processes (L-PBF / sinter AM).

An Overview of DED Processes

WAAM or Laser Wire Deposition Welding

Just as in comparison with laser powder deposition welding, WAAM systems are significantly less expensive than DED-LB/w systems. In most cases, large components can be manufactured more cost-effectively and quickly using WAAM.

 

However, the higher heat input leads to greater warpage, residual stress, and an increased risk of cracking. In WAAM, process-monitoring sensors (e.g., cameras, thermography) can only be positioned off-axis, unlike in laser welding. 

An Overview of DED Processes

FAQ

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  • In general, all weldable metals can be processed using WAAM. WAAM uses commercially available welding wires. The range of materials is very broad and includes, among others, steels, stainless steels, aluminum, titanium, and nickel-based alloys. 

  • The surface of the components resembles weld seams. They have a rough, sometimes ridged surface. Dimensional accuracy ranges from +/- 1 to 2 millimeters. Final dimensional accuracy and smooth surfaces usually require mechanical finishing (CNC milling or turning).

  • Instead of completely replacing expensive components—such as a turbine shaft or a large valve—when they wear out or become defective, companies can repair them cost-effectively using WAAM. In this process, the damaged material is first removed, then precisely rewelded using WAAM, and finally machined. 

  • Multi-axis robots or gantry systems are typically used for WAAM. The maximum component size is almost exclusively limited by the range of the motion axis. The components can be several meters in size. 

  • No. For most standard materials, a local shielding gas supply directly at the welding torch is sufficient. Only for materials that are extremely susceptible to oxidation, such as titanium, may additional shielding gas enclosures or devices to protect the component during cooling be necessary.

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