New Wire Additive Manufacturing (NEWAM)

Lead Research Organisation: CRANFIELD UNIVERSITY
Department Name: Sch of Aerospace, Transport & Manufact

Abstract

3D printing, or, Additive Manufacturing (AM), has rapidly come to prominence as a valid and convenient alternative to other production techniques, this is thanks to a growing body of evidence that its advantages in terms of lead-time reduction; design flexibility and capability; and reduced manufacturing waste are not only potential, but very much real. Metal AM techniques can be categorised based upon the form of the material they use (powder or wire), the heat source (laser, electron beam, or electric arc), or the way the material is delivered (pre-placed bed, or direct feed). Each of the metal AM technologies, given its particular properties, is best suited for specific applications. For example, the selective laser-melting of a pre-placed powder bed yields precise, net-shape components that can be very complex in design. However, their size is limited, cost is high, and build rates are low. In contrast, the Directed Energy Deposition (DED) processes can build near-net-shape parts, at many kilograms per hour, and with potentially no limitation to a components' size. To date, most of the work in wire based DED has been carried out at Cranfield University, where a 6-m-long aluminium aero-structure was built in a few days. Research over the last 10 years has also proven the capability to make large titanium parts in a timely manner (weeks instead of months) and with much reduced cost (up to 70% cheaper than machining from solid), resulting in a tremendous industry pull.

However, manufacturing such components is extremely challenging; so far, it has been based on engineering principles; a great deal of empirical know-how is required for every new application, leading to long lead times and high cost for new applications and materials. These are ever-varying and numerous, in light of the heterogeneity of the end-users mix. Therefore, there is an urgent need to develop a science-based understanding of DED processing; this is key to exploit its full potential and enable the industrial pick-up it merits. Such potential could be increased by combining more than one process: E.g. an arc and a laser could be coupled into one symbiotic machine, generating a multiple energy source configuration.

Our vision is to radically transform Large Area Metal Additive (LAMA) manufacturing, by pioneering:
- new high build-rate wire based DED with greater precision of shape and microstructure
- production of net-shape large-scale engineering structures, at low cost
- guaranteed 'right-first-time' homogeneous or tailored high performance properties and structural integrity.

Four universities (Cranfield U., U. of Manchester, Strathclyde U., and Coventry U.) have joined forces to deliver this ambitious research programme over five years with a budget of £7M. The LAMA programme is formed by four interconnected projects:
1. LAMA's engine room. New wire-based DED processes with two primary aims: simultaneous high build rate with precision net-shape deposition (no finishing process required); and independent thermal control from deposition shape, using active thermal profile management.
2. LAMA's design room: new wire compositions tailored to the newly available thermal process regimes, and capable of producing properties better than the equivalent forged alloys; it will also provide crucial information regarding the formation and criticality of defects.
3. LAMA's modelling room: key fundamental science and understanding, using advanced process and material modelling and state-of-the-art high efficiency techniques. Physics-based thermal and fluid-flow models, as well as microstructural and mechanical models will be developed and implemented.
4. LAMA's quality room: physics-based framework for guaranteed mechanical properties and structural integrity in as-built components; including the development of in-process non-destructive evaluation techniques.

LAMA will build on and exploit the UK's substantial lead in wire-based DED technology.

Planned Impact

The research outputs from LAMA will include
- New additive manufacturing (AM) or 3D printing processes for metals with greatly enhanced capability and level of control
- New concepts or feedstock material including compositions, novel shapes and new configurations
- A radically different approach to guaranteeing that component manufactured using these new processes and materials is fit for purpose in demanding structural applications, such as in aircraft manufacture
These are all highly beneficial for UK industry, including end-users of the research outputs from LAMA, as well as the whole supply chain for this new technology. End-users include many industry sectors such as aerospace, defence, energy (including renewables and nuclear), and construction. The new AM processes and materials will lead to significantly reduced manufacturing costs and lead times, combined with much higher productivity. This will make these UK industries much more competitive internationally. LAMA will also give the opportunity for UK businesses to lead the supply chain for these new AM processes, including specialist hardware, lasers, and feedstock materials; providing a major opportunity for export worldwide,
Moreover, the high level of benefit to industry of LAMA will generate significant economic benefit for the UK economy as a whole.
Societal benefits will include generation or retention of jobs in key industry sectors within the UK. The new AM process will also provide major environmental benefits as they are targeted at replacement of high consumption manufacturing methods, such as machining material out solid blocks of metal. Material savings of up to 80% are likely leading to a much sustainable manufacturing capability. Furthermore, many of these materials are highly energy intensive to produce, so that large energy saving will be achieved along with the consequent reduction in CO2 emissions.

Publications

10 25 50

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Lines D (2020) A flexible robotic cell for in-process inspection of multi-pass welds in Insight - Non-Destructive Testing and Condition Monitoring

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Barrionuevo G (2022) A machine learning approach for the prediction of melting efficiency in wire arc additive manufacturing in The International Journal of Advanced Manufacturing Technology

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Mohseni E (2020) A Model-Based Study of Transmit-Receive Longitudinal Arrays for Inspection of Subsurface Defects in Journal of Nondestructive Evaluation, Diagnostics and Prognostics of Engineering Systems

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Michel F (2019) A modular path planning solution for Wire + Arc Additive Manufacturing in Robotics and Computer-Integrated Manufacturing

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Bandari Y.K. (2020) Additive manufacture of large structures: Robotic or CNC systems? in Proceedings - 26th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2015

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Davis G. (2022) Automated laser induced phased arrays for the rapid ultrasonic inspection of AM components in 59th Annual Conference of the British Institute of Non-Destructive Testing, NDT 2022

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Suder W (2024) Control of meltpool shape in laser welding in Welding in the World

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Eimer E (2024) From Wire to Component: Aluminium Lithium Alloy Development for Wire and Arc Additive Manufacturing in BHM Berg- und Hüttenmännische Monatshefte

 
Title 3D Printing Titanium with a Conical Electron Beam 
Description We teamed up with xBeam 3D Metal Printing (https://xbeam3d.com/) to characterise Ti-6Al-4V (Ti64) parts 3D printed using wire and a conical electron beam. In this video, I analyse the ß-grain structures of the xBeam test parts, built with 3 different deposition strategies, and present a post-build heat treatment trial to demonstrate that the xBeam process can replicate wrought titanium aerospace parts. Original research paper: https://doi.org/10.1016/j.mtla.2021.101202 xBeam 3D Metal Printing: https://xbeam3d.com/ Research credits: Alec. E Davis, J. R. Kennedy, D. Strong, D. Kovalchuk, S. Porter, P. B. Prangnell. Video credits: Produced, written, recorded, and performed by Alec E. Davis. 
Type Of Art Film/Video/Animation 
Year Produced 2023 
URL https://zenodo.org/record/7620198
 
Title Achieving Nanoscale Resolution with EBSD 
Description Struggling to map nanoscale features in your microstructures with EBSD? Perhaps this video can help... (Case study: indexing the ß phase in Ti-6Al-4V). Original research paper: https://doi.org/10.1016/j.matchar.2022.112371 Research credits: A. E. Davis, X. Zeng, R. Thomas, J. R. Kennedy, J. Donoghue, A. Gholinia, P. B. Prangnell. Video credits: Produced, written, and performed by Alec E. Davis. Recorded by Alec E. Davis, Jack Donoghue, and Vivek Sahu. This work was supported by grants: Lightform (EPSRC EP/R001715/1), NEWAM (EPSRC EP/R027218/1), and Henry Royce Institute for Advanced Materials (EPSRC EP/R00661X/1, EP/S019367/1, EP/P025021/1, and EP/P025498/1). Alec E. Davis is also appreciated for equipment loan from the @materialsavclub. Commercial EBSD indexing software links: Oxford Instruments: https://www.oxinst.com/blogs/pattern-matching-a-paradigm-shift-for-ebsd EDAX: https://www.edax.com/resources/application-notes/spherical-indexing 
Type Of Art Film/Video/Animation 
Year Produced 2023 
URL https://zenodo.org/record/8015534
 
Title Additively Manufactured Titanium 'Alloy-Alloy Composites' and Site-Specific Property Design 
Description Paper links: Journal of Materials Characterization: https://doi.org/10.1016/j.matchar.2021.111577 Research Gate (free preprint): https://bit.ly/3xy1Ldm Video written and produced by Alec Davis and Jacob Kennedy. Research was conducted at the University of Manchester and Cranfield University, UK, by Jacob Kennedy, Alec Davis, Armando Caballero, Michael White, Jon Fellowes, Ed Pickering, and Phil Prangnell. This work was supported by grants: NEWAM (EPSRC EP/R027218/1), Lightform (EPSRC EP/R001715/1), and Henry Royce Institute for Advanced Materials (EPSRC EP/R00661X/1, EP/S019367/1, EP/P025021/1, and EP/P025498/1). 
Type Of Art Film/Video/Animation 
Year Produced 2021 
URL https://zenodo.org/record/7014852
 
Title Alec Davis ICOTOM19 conference presentation 
Description Simulation and texture investigation of a novel recrystallisation mechanism in Ti-6Al-4V during wire-arc AM with inter-pass deformation. High deposition rate Wire-Arc Additive Manufacture (WAAM) of Ti-6Al-4V is attractive to industry for near-net shape production of large-scale components. However, WAAM leads to the development of undesirable coarse columnar ß grains which, as a consequence of the larger heat source, grow epitaxially throughout components. To break up the ß-grain structure, a cold deformation step can be introduced, between deposition passes, to induce recrystallisation on heating during the a?ß transformation. This inter-pass deformation process produces small, equiaxed, ß grains, even when low strains are employed. In single ß crystal simulations of the thermomechanical history, starting with a coarse conventional a microstructure, the more expected behaviour occurred, with limited ß recrystallisation produced largely by lattice rotation. In contrast, with a fine AM starting transformation microstructure, as well as a high level of recrystallisation, a unique texture was observed, which was consistent with the deformation-induced annealing twinning produced during the a?ß transformation. 
Type Of Art Film/Video/Animation 
Year Produced 2021 
URL https://zenodo.org/record/7014449
 
Title Beta-Stabilised Titanium Alloys - Superalloy lecture 7 
Description This set of lectures is on "Beta-Stabilised Titanium Alloys" for the Superalloys & High Performance Materials course part 7. This part of the course was taught by Dr Alec Davis at The University of Manchester in 2021.Video 1 covers the history, general properties, and classification of beta-stabilised titanium alloys.Video 2 covers the phases and age hardening behaviour of beta-stabilised titanium, and a brief overview of the characterisation techniques is also given.Video 3 covers the thermomechanical processing of beta-stabilised titanium alloys.The live lecture includes a group discussion on thermomechanical processing and covers the "Beta-stabilised titanium alloys" topic. It was recorded on Thursday 18th March 2021. 
Type Of Art Film/Video/Animation 
Year Produced 2021 
URL https://figshare.manchester.ac.uk/articles/media/Beta-Stabilised_Titanium_Alloys_-_Superalloy_lectur...
 
Title Beta-Stabilised Titanium Alloys - Superalloy lecture 7 
Description This set of lectures is on "Beta-Stabilised Titanium Alloys" for the Superalloys & High Performance Materials course part 7. This part of the course was taught by Dr Alec Davis at The University of Manchester in 2021.Video 1 covers the history, general properties, and classification of beta-stabilised titanium alloys.Video 2 covers the phases and age hardening behaviour of beta-stabilised titanium, and a brief overview of the characterisation techniques is also given.Video 3 covers the thermomechanical processing of beta-stabilised titanium alloys.The live lecture includes a group discussion on thermomechanical processing and covers the "Beta-stabilised titanium alloys" topic. It was recorded on Thursday 18th March 2021. 
Type Of Art Film/Video/Animation 
Year Produced 2021 
URL https://figshare.manchester.ac.uk/articles/media/Beta-Stabilised_Titanium_Alloys_-_Superalloy_lectur...
 
Title Data supporting "A novel cold wire gas metal arc (CW-GMA) process for high productivity additive manufacturing" 
Description This is a supplementary figure, showing the experimental setup for building the large-scale component with the CW-GMA process: (a) experiment setup, and (b) monitors for thermal camera and process camera. 
Type Of Art Film/Video/Animation 
Year Produced 2023 
URL https://cord.cranfield.ac.uk/articles/figure/Data_supporting_A_novel_cold_wire_gas_metal_arc_CW-GMA_...
 
Title Efficient reduced-order thermal modelling of scanning laser melting for additive manufacturing. 
Description Thermal videos show the dynamic changing of the scanning laser melt pools with different oscillation frequencies 
Type Of Art Film/Video/Animation 
Year Produced 2023 
URL https://cord.cranfield.ac.uk/articles/media/Efficient_reduced-order_thermal_modelling_of_scanning_la...
 
Title How many large samples can you scan with EBSD at once? 
Description In this video, I helped Xiaohan Zeng set up an EBSD run of 10 Ti-6Al-4V samples in a row on a Thermo Fisher high throughput Apreo SEM equipped with an Oxford Instruments' Symmetry 2 detector at the University of Manchester, UK. EBSD scan setup by Xiaohan Zeng (assisted by Dr Alec E Davis), sample preparation by Xiaohan Zeng, EBSD mapping calculator created by Dr Jack Donoghue. This research was supported by grants: NEWAM (EPSRC EP/R027218/1), LightForm (EPSRC EP/R001715/1), Henry Royce Institute for Advanced Materials (EPSRC EP/R00661X/1, EP/S019367/1, EP/P025021/1, and EP/P025498/1). 
Type Of Art Film/Video/Animation 
Year Produced 2021 
URL https://zenodo.org/record/5384028
 
Title Hybrid PTA-laser melting process 
Description This is a supplementary video showing the hybrid PTA-laser melting process. 
Type Of Art Film/Video/Animation 
Year Produced 2023 
URL https://cord.cranfield.ac.uk/articles/media/Hybrid_PTA-laser_melting_process/21923409
 
Title Multi-Energy Source (MES) Configuration for Bead Shape Control in Wire-based Directed Energy Deposition (w-DED) 
Description Video shows the the dynamic changing of the melt pool and highspeed scanning motion of the laser beam. 
Type Of Art Film/Video/Animation 
Year Produced 2022 
URL https://cord.cranfield.ac.uk/articles/media/Multi-Energy_Source_MES_Configuration_for_Bead_Shape_Con...
 
Title Multi-Energy Source (MES) Configuration for Bead Shape Control in Wire-based Directed Energy Deposition (w-DED) 
Description Video shows the the dynamic changing of the melt pool and highspeed scanning motion of the laser beam. 
Type Of Art Film/Video/Animation 
Year Produced 2022 
URL https://cord.cranfield.ac.uk/articles/media/Multi-Energy_Source_MES_Configuration_for_Bead_Shape_Con...
 
Title Nickel-Base Superalloy Precipitation - Superalloy Lecture 11 
Description This set of lectures is on "Nickel-Base Superalloy Precipitation" for the Superalloys & High Performance Materials course part 11. This part of the course was taught by Dr Alec Davis at The University of Manchester in 2021.Video 1 gives an overview of the precipitation in nickel-base superalloy precipitation.Video 2 covers the impact of precipitation on mechanical properties in nickel-base superalloys.The live lecture includes poll questions on the nickel-base superalloy precipitation topic, and the deformation mechanisms were covered in more detail. It was recorded on 19th April 2021. 
Type Of Art Film/Video/Animation 
Year Produced 2021 
URL https://figshare.manchester.ac.uk/articles/media/Nickel-Base_Superalloy_Precipitation_-_Superalloy_L...
 
Title Nickel-Base Superalloy Precipitation - Superalloy Lecture 11 
Description This set of lectures is on "Nickel-Base Superalloy Precipitation" for the Superalloys & High Performance Materials course part 11. This part of the course was taught by Dr Alec Davis at The University of Manchester in 2021.Video 1 gives an overview of the precipitation in nickel-base superalloy precipitation.Video 2 covers the impact of precipitation on mechanical properties in nickel-base superalloys.The live lecture includes poll questions on the nickel-base superalloy precipitation topic, and the deformation mechanisms were covered in more detail. It was recorded on 19th April 2021. 
Type Of Art Film/Video/Animation 
Year Produced 2021 
URL https://figshare.manchester.ac.uk/articles/media/Nickel-Base_Superalloy_Precipitation_-_Superalloy_L...
 
Title Real-time observation of alpha nucleation in Ti-6Al-4V 
Description This video was captured during an in-situ heating stage SEM experiment using a secondary electron camera at the University of Manchester, UK. The Ti-6Al-4V sample was heated to 1000°C to the full ß-phase field and then slowly cooled (0.3°C/s) through the ß transus, and the a-phase nucleation was recorded by the contrast change in the secondary electron camera from topography development on the sample surface due to surface relief. Microscope operated by Dr Alec E Davis and Dr Jack Donoghue, sample preparation by Nick Byres. These results were published in an Acta Materialia paper in 2021: Acta Materialia paper: https://doi.org/10.1016/j.actamat.2021.117315 Researchgate (free peer reviewed preprint): https://bit.ly/3EHs7Na 
Type Of Art Film/Video/Animation 
Year Produced 2021 
URL https://zenodo.org/record/7014489
 
Title Setting up an ENORMOUS sample EBSD! 
Description Setting up an EBSD of an 8 x 6 cm Ti-6Al-4V deformed metallic sample on a Thermo Fisher Apreo SEM equipped with an Oxford Instruments' Symmetry 2 detector at the University of Manchester, UK. EBSD scan setup by Dr Alec E Davis, sample preparation by Nicholas Byres, EBSD mapping calculator created by Dr Jack Donoghue. This research was supported by grants: NEWAM (EPSRC EP/R027218/1), LightForm (EPSRC EP/R001715/1), Henry Royce Institute for Advanced Materials (EPSRC EP/R00661X/1, EP/S019367/1, EP/P025021/1, and EP/P025498/1). 
Type Of Art Film/Video/Animation 
Year Produced 2021 
URL https://zenodo.org/record/4947964
 
Title The Metallurgy of Titanium Additive Manufacturing - Superalloy Lecture 13 
Description This set of lectures is on "The Metallurgy of Titanium Additive Manufacturing" for the Superalloys & High Performance Materials course part 13. This part of the course was taught by Dr Alec Davis at The University of Manchester in 2021.Video 1 discusses the formation of large beta grain structures in high deposition rate additively manufactured titanium and the methods of breaking up this structure.Video 2 discusses the effect of repeated rapid heating cycles on the alpha transformation microstructure in titanium additive manufacturing.The live lecture includes a group discussion on the impact of repeated rapid heating cycles that are intrinsic to additive manufacturing on various titanium alloys, and was recorded on 26th April 2021. 
Type Of Art Film/Video/Animation 
Year Produced 2021 
URL https://figshare.manchester.ac.uk/articles/media/The_Metallurgy_of_Titanium_Additive_Manufacturing_-...
 
Title The Metallurgy of Titanium Additive Manufacturing - Superalloy Lecture 13 
Description This set of lectures is on "The Metallurgy of Titanium Additive Manufacturing" for the Superalloys & High Performance Materials course part 13. This part of the course was taught by Dr Alec Davis at The University of Manchester in 2021.Video 1 discusses the formation of large beta grain structures in high deposition rate additively manufactured titanium and the methods of breaking up this structure.Video 2 discusses the effect of repeated rapid heating cycles on the alpha transformation microstructure in titanium additive manufacturing.The live lecture includes a group discussion on the impact of repeated rapid heating cycles that are intrinsic to additive manufacturing on various titanium alloys, and was recorded on 26th April 2021. 
Type Of Art Film/Video/Animation 
Year Produced 2021 
URL https://figshare.manchester.ac.uk/articles/media/The_Metallurgy_of_Titanium_Additive_Manufacturing_-...
 
Title Thermal fluid dynamics of the effect of filler wire on deposition rate and bead formation intending plasma arc-based DED 
Description Videos of the simulations generated by this research. 
Type Of Art Film/Video/Animation 
Year Produced 2023 
URL https://cord.cranfield.ac.uk/articles/media/Thermal_fluid_dynamics_of_the_effect_of_filler_wire_on_d...
 
Title Titanium Aluminide Intermetallics - Superalloy Lecture 8 
Description This set of lectures is on "Titanium Aluminide Intermetallics" for the Superalloys & High Performance Materials course part 8. This part of the course was taught by Dr Alec Davis at The University of Manchester in 2021.Video 1 covers the applications and common phases found in titanium aluminide intermetallic alloys.Video 2 covers the deformation mechanisms, thermomechanical processing, and grain refinement techniques of titanium aluminide intermetallic alloys.Video 3 covers the effect of high temperature environments on titanium and titanium aluminide intermetallic alloys, and the specific metallurgy of how these alloys maintain high strengths and oxidation resistance at elevated temperatures are discussed.The live lecture includes poll questions on the titanium aluminide intermetallics topic and a group discussion on grain refinement. It was recorded on 12th April 2021. 
Type Of Art Film/Video/Animation 
Year Produced 2021 
URL https://figshare.manchester.ac.uk/articles/media/Titanium_Aluminide_Intermetallics_-_Superalloy_Lect...
 
Title Titanium Aluminide Intermetallics - Superalloy Lecture 8 
Description This set of lectures is on "Titanium Aluminide Intermetallics" for the Superalloys & High Performance Materials course part 8. This part of the course was taught by Dr Alec Davis at The University of Manchester in 2021.Video 1 covers the applications and common phases found in titanium aluminide intermetallic alloys.Video 2 covers the deformation mechanisms, thermomechanical processing, and grain refinement techniques of titanium aluminide intermetallic alloys.Video 3 covers the effect of high temperature environments on titanium and titanium aluminide intermetallic alloys, and the specific metallurgy of how these alloys maintain high strengths and oxidation resistance at elevated temperatures are discussed.The live lecture includes poll questions on the titanium aluminide intermetallics topic and a group discussion on grain refinement. It was recorded on 12th April 2021. 
Type Of Art Film/Video/Animation 
Year Produced 2021 
URL https://figshare.manchester.ac.uk/articles/media/Titanium_Aluminide_Intermetallics_-_Superalloy_Lect...
 
Title Video for Fig. 4b 
Description This is a supplementary video for Fig 4b, showing the hybrid PTA-laser melting process with a laser leading configuration. 
Type Of Art Film/Video/Animation 
Year Produced 2022 
URL https://cord.cranfield.ac.uk/articles/media/Video_for_Fig_4b/19330580
 
Title Videos for Fig. 15 with a small and a large laser beam diameter, respectively. 
Description These are two supplementary videos for Fig 15, showing deposition process with two different laser beam diameters (12 mm and 2 mm, respectively) in wire based PTA-laser hybrid additive manufacture. 
Type Of Art Film/Video/Animation 
Year Produced 2021 
URL https://cord.cranfield.ac.uk/articles/media/Videos_for_Fig_15_with_a_small_and_a_large_laser_beam_di...
 
Title Videos for Fig. 15 with a small and a large laser beam diameter, respectively. 
Description These are two supplementary videos for Fig 15, showing deposition process with two different laser beam diameters (12 mm and 2 mm, respectively) in wire based PTA-laser hybrid additive manufacture. 
Type Of Art Film/Video/Animation 
Year Produced 2021 
URL https://cord.cranfield.ac.uk/articles/media/Videos_for_Fig_15_with_a_small_and_a_large_laser_beam_di...
 
Title Videos for Fig. 5 with PTA leading and laser leading, respectively. 
Description These are two supplementary videos for Fig 5, showing different configurations for wire based PTA-laser hybrid additive manufacturing process. 
Type Of Art Film/Video/Animation 
Year Produced 2021 
URL https://cord.cranfield.ac.uk/articles/media/Videos_for_Fig_5_with_PTA_leading_and_laser_leading_resp...
 
Title Videos for Fig. 5 with PTA leading and laser leading, respectively. 
Description These are two supplementary videos for Fig 5, showing different configurations for wire based PTA-laser hybrid additive manufacturing process. 
Type Of Art Film/Video/Animation 
Year Produced 2021 
URL https://cord.cranfield.ac.uk/articles/media/Videos_for_Fig_5_with_PTA_leading_and_laser_leading_resp...
 
Description The original patented concept for the new method of 3D printing of metals at high speed has been experimentally demonstrated. This has now been used to investigate the control of properties in titanium alloys
Non Destructive Testing (NDT) and process monitoring methods for the 3D printing methods have been developed to enable real time inspection and control. The NDT and 3D printing has been combined together to demonstrate in-process inspection.
Advanced process and materials models have been developed and are now linked together to enable prediction of material properties from process conditions
Full control of microstructure in Ti64 alloy has been demonstrated and better than wrought properties achieved
A new very high build rate process has been developed achieving more than 15kg/hr for steels and 10kg/hr for titanium alloys
Exploitation Route The output from the project could be used by our spin out company WAAM3D to improve the technical capability of the systems that they provide.
Sectors Aerospace

Defence and Marine

Construction

Energy

Manufacturing

including Industrial Biotechology

Transport

URL https://newam.uk/
 
Description The new sensor for shape measurement has now been incorporated in WAAM3D first commercial WAAM system. The new CWMIG process is being integrated into WAAM3D RoboWAAM system
First Year Of Impact 2022
Sector Manufacturing, including Industrial Biotechology
Impact Types Economic

 
Description Discussion with CTO of High Value Manufacturing Catapult on how to best engage with centres in the HVMC
Geographic Reach National 
Policy Influence Type Influenced training of practitioners or researchers
 
Description MSc Course - Additive Manufacture
Geographic Reach Multiple continents/international 
Policy Influence Type Influenced training of practitioners or researchers
Impact The MSc course contributes to increase number of skilled people working in additive manufacturing (AM). When compared to the traditional manufacturing processes, AM offers a significant cost saving by reducing the amount of material used and processing time. AM is also an environmentaly friendly process because less material is used and wasted during manufacturing of large industrial components.
 
Description Short course - Advanced Welding Processes - Laser welding
Geographic Reach National 
Policy Influence Type Influenced training of practitioners or researchers
Impact Increase number of skilled people working in laser processing
 
Description Boeing support for NEWAM
Amount £150,000 (GBP)
Organisation Boeing 
Sector Private
Country United States
Start 11/2020 
End 11/2022
 
Description Coherent range-resolved interferometry (Co-RRI) sensor development and integration for WAAM
Amount £50,295 (GBP)
Organisation WAAM3D Limited 
Sector Private
Country United Kingdom
Start 02/2021 
End 11/2021
 
Description Fabrication of titanium demonstrator components
Amount £300,000 (GBP)
Organisation Boeing 
Sector Private
Country United States
Start 05/2022 
End 11/2024
 
Description Framework agreement
Amount £1,000,000 (GBP)
Organisation General Electric 
Sector Private
Country United States
Start 11/2023 
End 11/2026
 
Description High Productivity Wire Arc Additive Manufacturing (HPWAAM)
Amount £1,220,291 (GBP)
Funding ID 53610 
Organisation Innovate UK 
Sector Public
Country United Kingdom
Start 11/2020 
End 10/2023
 
Description I-Break: Wire based DED, technology maturation and landing gear application
Amount £15,393,193 (GBP)
Organisation Innovate UK 
Sector Public
Country United Kingdom
Start 03/2022 
End 06/2025
 
Description Multifun
Amount € 8,320,000 (EUR)
Funding ID P12842 
Organisation European Commission H2020 
Sector Public
Country Belgium
Start 03/2020 
End 02/2023
 
Description Process Development with WAAM process for new titanium alloy
Amount £68,700 (GBP)
Organisation WAAM3D Limited 
Sector Private
Country United Kingdom
Start 03/2021 
End 03/2023
 
Description Sprint Hybrid Direct Energy Deposition
Amount £180,000 (GBP)
Organisation Aerospace Technology Institute 
Sector Charity/Non Profit
Country United Kingdom
Start 03/2021 
End 09/2022
 
Description Sustainable Additive Manufacture - SAM
Amount £1,638,781 (GBP)
Funding ID EP/W01906X/1 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 05/2022 
End 05/2025
 
Description Testing of high deposition rate Wire + Arc Additive Manufacture (HiDep-WAAM) plasma process
Amount £30,000 (GBP)
Organisation WAAM3D Limited 
Sector Private
Country United Kingdom
Start 01/2023 
End 06/2023
 
Description Thermal monitoring instrumentation for metal additive manufacturing - PYRAM
Amount £961,862 (GBP)
Funding ID EP/W025035/1 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 03/2023 
End 10/2026
 
Description WAAM for mining applications
Amount £35,000 (GBP)
Organisation Weir Group plc 
Sector Private
Country United Kingdom
Start 01/2022 
End 12/2022
 
Description WAAM of aluminium bulkheads for satellite applications
Amount £325,188 (GBP)
Organisation WAAM3D Limited 
Sector Private
Country United Kingdom
Start 06/2021 
End 08/2022
 
Description WAAM repair of cast iron components
Amount £150,000 (GBP)
Organisation Weir Group plc 
Sector Private
Country United Kingdom
Start 05/2022 
End 06/2023
 
Description WAAMMat Project: WAAM Manufacturing and technology transfer
Amount £60,000 (GBP)
Organisation Weir Group plc 
Sector Private
Country United Kingdom
Start 08/2021 
End 12/2022
 
Title Notch fatigue approach for predicting fatigue life reduction 
Description Notch fatigue approach for predicting fatigue life reduction due to porosity defects and also as-deposited surface waviness 
Type Of Material Improvements to research infrastructure 
Year Produced 2019 
Provided To Others? Yes  
Impact This new method has led to a publication by PhD researcher Biswal et al. 2019 in the Additive Manufacturing journal. 
URL https://www.sciencedirect.com/science/article/pii/S0142112319300295?via%3Dihub
 
Title Small crack growth 
Description Representation of small crack growth rate property by long crack test data 
Type Of Material Improvements to research infrastructure 
Year Produced 2021 
Provided To Others? Yes  
Impact This will save significant amount of testing time and resources in testing small cracks. This new method has led to the submission of a journal paper led by a PhD researcher to the Engineering Fracture Mechanics journal (submitted Feb 19th, 2021) 
 
Title Data supporting the publication 'In-process range-resolved interferometric (RRI) 3d layer height measurements for wire + arc additive manufacturing (WAAM)' 
Description Data and data analysis code supporting Institute of Physics, Measurement Science and Technology publication. 
Type Of Material Database/Collection of data 
Year Produced 2022 
Provided To Others? Yes  
URL https://cord.cranfield.ac.uk/articles/dataset/Data_supporting_the_publication_In-process_range-resol...
 
Title Data supporting: 'Modelling and optimising hybrid process of wire arc additive manufacturing and high-pressure rolling' 
Description Figure 7 Predicted distortion of the WAAM part after deactivation of clamps . Figure 8 Longitudinal RS distributions along the vertical path in the symmetry plane for the full-length mechanical models after clamps deactivation, compared to experimental measurements [5]. The flat roller (a) and slotted roller (b) were used in the rolling simulations, and the full-length model was based on the solution mapped from the steady-state region of the reduced-length WAAM + IL rolling model Figure 10 Concurrent evolution of temperature and longitudinal stress (a), as well as the longitudinal PS (b), in the layer 6 during WAAM deposition of layers 6-8 in conjunction with IL rolling using the flat roller. The data were collected at the top of layer 6 in the inspection plane and the rolling phases are highlighted in the yellow shaded areas. Figure 11 Concurrent evolution of temperature and longitudinal stress (a), as well as longitudinal PS (b), in the layer 6 during WAAM deposition of layers 9-11 in conjunction with IL rolling using the flat roller. The data were collected at the top of layer 6 in the inspection plane and the rolling phases are highlighted in the yellow shaded areas. Figure 12 Concurrent evolution of temperature and longitudinal stress (a), as well as longitudinal PS (b), in the layer 6 during WAAM deposition of layers 12-14 in conjunction with IL rolling using the flat roller. The data were collected at the top of layer 6 in the inspection plane and the rolling phases are highlighted in the yellow shaded areas. Figure 13 Concurrent evolution of the longitudinal PS and stress in the layer 9 during WAAM deposition of layers 9-16 in conjunction with IL rolling using the slotted roller. The data were collected at the top of layer 9 in the inspection plane (the slotted roller started rolling on layer 6) and the rolling phases are highlighted in the yellow shaded areas. Figure 18 Evolution of longitudinal PS in the layer 6 during WAAM deposition and stacked 4L rolling with flat roller. The rolling phases are highlighted in the yellow shaded areas. 
Type Of Material Database/Collection of data 
Year Produced 2022 
Provided To Others? Yes  
URL https://cord.cranfield.ac.uk/articles/dataset/Data_supporting_Modelling_and_optimising_hybrid_proces...
 
Title Data supporting: 'Strain controlled fatigue behaviour of wire + arc additive manufactured Ti-6Al-4V' 
Description This paper investigates the strain controlled fatigue and cyclic deformation behaviour of a wire + arc additive manufactured Ti-6Al-4V alloy in the as-built condition. Higher local heat input used to build the material exhibited a coarser parent columnar ß grain structure along with a coarser transformation microstructure compared to other additive manufactured Ti-6Al-4V. Test specimens were manufactured in horizontal and vertical orientations with respect to the deposited layers. Property isotropy was observed at lower applied strain values. When the strain amplitude was above 0.6%, the vertical samples, where the loading axis was in parallel with the parent columnar ß grains, showed marginally higher fatigue strength owing to larger plastic deformation. Moreover, higher cyclic softening ratio by a factor of two was measured in the vertical samples when the strain amplitude was above 0.6%. No porosity defects were found in the material. Cracks were initiated from a lath due to cyclic slip localisation. 
Type Of Material Database/Collection of data 
Year Produced 2023 
Provided To Others? Yes  
URL https://cord.cranfield.ac.uk/articles/dataset/Data_supporting_Strain_controlled_fatigue_behaviour_of...
 
Title Data: Effect of machine hammer peening conditions on ß grain refinement of additively manufactured Ti-6Al-4V 
Description The data in this folder is a table with the average grain size according to variations of parameters studied. This information is given in the paper as a graphical representation and is here described to support any further studies. 
Type Of Material Database/Collection of data 
Year Produced 2023 
Provided To Others? Yes  
URL https://cord.cranfield.ac.uk/articles/dataset/Data_Effect_of_machine_hammer_peening_conditions_on_gr...
 
Title Data: Fatigue crack growth behavior in an aluminum alloy Al-Mg-0.3Sc produced by wire based directed energy deposition process 
Description Additive manufacturing (AM) of Al-Mg-Sc alloys has received considerable interest from the aerospace industry owing to their high specific strength and suitability for AM. Since damage tolerance is a mandatory requirement for safety critical aerospace structures, this study has investigated the fatigue crack growth behaviour in an Al-Mg-0.3Sc alloy made by the wire and arc additive manufacturing. Tests were conducted with two different crack orientations at load ratios 0.1 and 0.5. At the lower load ratio and lower stress intensity factor range (<10 MPa m1/2), crack growth rate was 50% lower when it propagated perpendicular to the material build direction owing to larger grains along the crack path that caused more resistance to crack growth. When the crack grew parallel with the build direction, the crack tip encountered both smaller and larger grain zones, periodically; smaller grains gave much lower resistance to crack growth. When higher stress intensity factor range exceeded>10 MPa m1/2, isotropic crack growth rate property was measured; grain size effect was overcome by the mechanical factor (the stress intensity factor). At the higher load ratio 0.5, both the threshold and the critical values of the stress intensity factor range were reduced. Finally, the modified Hartman-Schijve equation was successfully employed to represent the crack growth rates including the threshold and the fast crack growth regions. 
Type Of Material Database/Collection of data 
Year Produced 2023 
Provided To Others? Yes  
URL https://cord.cranfield.ac.uk/articles/dataset/Data_Fatigue_crack_growth_behavior_in_an_aluminum_allo...
 
Title Data: Thermo-Capillary-Gravity Bidirectional Modelling for Evaluation and Design of Wire-Based Directed Energy Deposition Additive Manufacturing 
Description In this study, a thermo-capillary-gravity bidirectional analytical model is developed based on the fundamental governing physics, enabling fast predictions of both w-DED bead geometries and process parameters. A novel method is also proposed to determine the power transfer efficiency and wire melting efficiency defined in the model. In the forward modelling, deposit bead geometries, such as layer height and width, can be predicted for given process parameters and material properties. In the reverse modelling, the outputs of the model are process parameters, including heat source power and travel speed, to achieve the deposit bead geometries as required for a given application. This bidirectional modelling approach is applicable to different w-DED processes, and it has been validated for the deposition of steel walls using plasma transferred arc and cold wire gas metal arc processes. The developed bidirectional analytical model could be used as an efficient and reliable tool for w-DED process evaluation and design. 
Type Of Material Database/Collection of data 
Year Produced 2023 
Provided To Others? Yes  
URL https://cord.cranfield.ac.uk/articles/dataset/Data_Thermo-Capillary-Gravity_Bidirectional_Modelling_...
 
Title Dataset for Computationally Efficient Models of High Pressure Rolling for Wire Arc Additively Manufactured Components 
Description 1. Dataset for Figure 5: Equivalent plastic strain obtained along centreline on the top of the WAAM wall.2. Dataset for Figure 6: Reaction forces obtained at the rotation point of the rollers (note that only half of the WAAM component was considered in the models).3. Dataset for Figure 13: Longitudinal PS distributions on inspection planes.4. Dataset for Figure 14: Longitudinal RS distributions on inspection planes. 
Type Of Material Database/Collection of data 
Year Produced 2021 
Provided To Others? Yes  
URL https://cord.cranfield.ac.uk/articles/dataset/Dataset_for_Computationally_Efficient_Models_of_High_P...
 
Title Dataset for Computationally Efficient Models of High Pressure Rolling for Wire Arc Additively Manufactured Components 
Description 1. Dataset for Figure 5: Equivalent plastic strain obtained along centreline on the top of the WAAM wall.2. Dataset for Figure 6: Reaction forces obtained at the rotation point of the rollers (note that only half of the WAAM component was considered in the models).3. Dataset for Figure 13: Longitudinal PS distributions on inspection planes.4. Dataset for Figure 14: Longitudinal RS distributions on inspection planes. 
Type Of Material Database/Collection of data 
Year Produced 2021 
Provided To Others? Yes  
URL https://cord.cranfield.ac.uk/articles/dataset/Dataset_for_Computationally_Efficient_Models_of_High_P...
 
Title Dataset for Efficient determination and evaluation of steady-state thermal-mechanical variables generated by wire arc additive manufacturing and high pressure rolling 
Description 1. Dataset for Figure 5: Temperature histories predicted by the short thermal WAAM model at the thermocouple locations: (a) TP1, (b) TP2, (c) TP3 and (d) TP4. The experimental measurements by Ding [34] are also included for comparison. 2. Dataset for Figure 11: Longitudinal RS distributions along the Z-direction (through wall height, see Figure 10b for the path of the line plots) in the mapped long mechanical model before and after clamps removal for the WAAM component. The experimental measurements by Ding et al. [34] and Colegrove et al. [5] are also included, which were conducted using neutron diffraction after clamps removal. 3. Dataset for Figure 12: Verification of out-of-plane distortion predicted by the mapped long mechanical model after clamps removal. Note that the experimental measurement by Ding [34] using a 3D laser scanner was based on a four-layer deposited wall, and the WAAM model was adapted accordingly. 
Type Of Material Database/Collection of data 
Year Produced 2021 
Provided To Others? Yes  
URL https://cord.cranfield.ac.uk/articles/dataset/Dataset_for_Efficient_determination_and_evaluation_of_...
 
Title Dataset for Efficient determination and evaluation of steady-state thermal-mechanical variables generated by wire arc additive manufacturing and high pressure rolling 
Description 1. Dataset for Figure 5: Temperature histories predicted by the short thermal WAAM model at the thermocouple locations: (a) TP1, (b) TP2, (c) TP3 and (d) TP4. The experimental measurements by Ding [34] are also included for comparison. 2. Dataset for Figure 11: Longitudinal RS distributions along the Z-direction (through wall height, see Figure 10b for the path of the line plots) in the mapped long mechanical model before and after clamps removal for the WAAM component. The experimental measurements by Ding et al. [34] and Colegrove et al. [5] are also included, which were conducted using neutron diffraction after clamps removal. 3. Dataset for Figure 12: Verification of out-of-plane distortion predicted by the mapped long mechanical model after clamps removal. Note that the experimental measurement by Ding [34] using a 3D laser scanner was based on a four-layer deposited wall, and the WAAM model was adapted accordingly. 
Type Of Material Database/Collection of data 
Year Produced 2021 
Provided To Others? Yes  
URL https://cord.cranfield.ac.uk/articles/dataset/Dataset_for_Efficient_determination_and_evaluation_of_...
 
Title Dataset for paper entitled 'Microstructure transition gradients in titanium dissimilar alloy (Ti-5Al-5V-5Mo-3Cr/Ti-6Al-4V) tailored wire-arc additively manufactured components' 
Description Dataset for paper entitled 'Microstructure transition gradients in titanium dissimilar alloy (Ti-5Al-5V-5Mo-3Cr/Ti-6Al-4V) tailored wire-arc additively manufactured components'. doi: https://doi.org/10.1016/j.matchar.2021.111577 
Type Of Material Database/Collection of data 
Year Produced 2022 
Provided To Others? Yes  
URL https://zenodo.org/record/5820274
 
Title Dataset for paper entitled 'Quantification of strain fields and grain refinement in Ti-6Al-4V inter-pass rolled wire-arc AM by EBSD misorientation analysis'. 
Description Dataset for paper entitled 'Quantification of strain fields and grain refinement in Ti-6Al-4V inter-pass rolled wire-arc AM by EBSD misorientation analysis'. doi: https://doi.org/10.1016/j.matchar.2020.110673 
Type Of Material Database/Collection of data 
Year Produced 2022 
Provided To Others? Yes  
URL https://zenodo.org/record/5822709
 
Title Dataset for paper entitled, 'Confirmation of rapid-heating ß recrystallization in wire-arc additively manufactured Ti-6Al-4V'. 
Description Dataset for paper entitled, 'Confirmation of rapid-heating ß recrystallization in wire-arc additively manufactured Ti-6Al-4V'. doi: https://doi.org/10.1016/j.mtla.2020.100857 
Type Of Material Database/Collection of data 
Year Produced 2022 
Provided To Others? Yes  
URL https://zenodo.org/record/5822996
 
Title Dataset for paper entitled, 'Isomorphic grain inoculation in Ti-6Al-4V during additive manufacturing' 
Description Dataset for paper entitled, 'Isomorphic grain inoculation in Ti-6Al-4V during additive manufacturing'. Abstract: The potential for using isomorphic inoculation (ISI) to grain refine titanium alloys in additive manufacturing was investigated by adding TiAlNb particles to Ti-64 during building test samples. A surviving particle was identified and its crystallographic relationship with the matrix studied by transmission Kikuchi diffraction. The particle and bulk matrix grain were shown to have the same crystallographic orientation, demonstrating that the ISI mechanism of solidification bypasses the nucleation step in favour of direct epitaxial growth. Paper doi: https://doi.org/10.1016/j.mlblux.2020.100057 
Type Of Material Database/Collection of data 
Year Produced 2020 
Provided To Others? Yes  
URL https://zenodo.org/record/5708634
 
Title Dataset for paper entitled, 'Tailoring equiaxed ß-grain structures in Ti-6Al-4V coaxial electron beam wire additive manufacturing' 
Description Dataset for paper entitled, 'Tailoring equiaxed ß-grain structures in Ti-6Al-4V coaxial electron beam wire additive manufacturing'. Abstract: High-deposition-rate, directed-energy-deposition additive manufacturing (DED-AM) processes typically produce Ti-6Al-4V (Ti64) components with coarse columnar ß-grain structures that lead to undesirable mechanical anisotropy, as well as a fine heterogeneous lamellar transformation microstructure, which is very different to that seen standard wrought products. This arises because of the intrinsic lack of constitutional undercooling at the solidification front, and the subsequent high cooling rates and rapid thermal cycling experienced by the deposited material. In this work, the more refined primary ß-grain solidification structures and textures seen in components built with the novel coaxial electron beam wire DED AM (CEWAM) process have been characterised in detail, for the first time, with the aim of investigating the potential for this technology to directly replicate the ß-annealed damage-tolerant microstructure used in large Ti64 aerospace forgings. Due to its different lower energy density solidification conditions, it has been confirmed, by electron backscatter diffraction (EBSD) analysis and ß-grain reconstruction in three orthogonal cross-sections, that the CEWAM process changes the melt conditions to promote ß-grain nucleation ahead of the solidification front, which can result in a highly refined, equiaxed, ß-grain structure. However, the conditions for refinement were marginal and a mixed grain structure was commonly observed in thicker sections. Additionally, the subsequent grain-growth stability during ß-annealing was investigated. It is shown that an equivalent microstructure can be achieved to that seen in a standard ß-forged component, by grain structure homogenisation and slow cooling through the ß transus, to promote a colony nucleation, allowing direct part substitution. This was made possible by the refined primary ß-grain structure achieved during deposition with the CEWAM solidification conditions which, importantly, are also shown to lead to a weaker texture than in a typical forging. Paper doi: https://doi.org/10.1016/j.mtla.2021.101202 
Type Of Material Database/Collection of data 
Year Produced 2021 
Provided To Others? Yes  
URL https://zenodo.org/record/5708646
 
Title Dataset for paper entitled, 'The potential for grain refinement of Wire-Arc Additive Manufactured (WAAM) Ti-6Al-4V by ZrN and TiN inoculation' 
Description Dataset for paper entitled, 'The potential for grain refinement of Wire-Arc Additive Manufactured (WAAM) Ti-6Al-4V by ZrN and TiN inoculation'. Abstract: Wire-Arc Additive Manufacturing (WAAM) of large near-net-shape titanium components has the potential to reduce costs and lead-time in many industrial sectors including aerospace. However, with titanium alloys, such as Ti-6Al-4V, standard WAAM processing conditions result in solidification microstructures comprising large cm- scale, <001> fibre textured, columnar ß grains, which are detrimental to mechanical performance. In order to reduce the size of the solidified ß-grains, as well as refine their columnar morphology and randomise their texture, two cubic nitride phases, TiN and ZrN were investigated as potential grain refining inoculants. To avoid the cost of manufacturing new wire, experimental trials were performed using powder adhered to the surface of the deposited tracks. With TiN particle additions, the ß grain size was successfully reduced and modified from columnar to equiaxed grains, with an average size of 300 µm, while ZrN powder was shown to be ineffective at low addition levels studied. Clusters of TiN particles were found to be responsible for nucleating multiple ß Ti grains. By utilizing the Burgers orientation relationship, EBSD investigation showed that a Kurdjumov-Sachs orientation relationship could be demonstrated between the refined primary ß grains and TiN particles. Paper doi: https://doi.org/10.1016/j.addma.2021.101928 
Type Of Material Database/Collection of data 
Year Produced 2021 
Provided To Others? Yes  
URL https://zenodo.org/record/5708618
 
Title Effect of substrate alloy type on the hardness profile of the substrate and deposited material interface in Aluminium Wire + Arc Additive Manufacturing 
Description This file provides the hardness measurements used in the paper to plot the different hardness profiles in figures 3 and 9 and the chemical composition measurement displayed in figure 10. 
Type Of Material Database/Collection of data 
Year Produced 2021 
Provided To Others? Yes  
URL https://cord.cranfield.ac.uk/articles/dataset/Effect_of_substrate_alloy_type_on_the_hardness_profile...
 
Title Hardness profile of the interface between the substrate and deposited material in Aluminium Wire + Arc Additive Manufacturing 
Description This file provides the hardness measurement presented in the paper. The measurement are provided for all combination of alloy presented using the convention substrate alloy + WAAM alloy. The alloy combination are given in the sheet name. 
Type Of Material Database/Collection of data 
Year Produced 2023 
Provided To Others? Yes  
URL https://cord.cranfield.ac.uk/articles/dataset/Hardness_profile_of_the_interface_between_the_substrat...
 
Title Knowledge-based bi-directional thermal variable modelling for directed energy deposition additive manufacturing (DED-AM) 
Description This dataset is used as the machine learning modelling training dataset in the paper- Knowledge-based bi-directional thermal variable modelling for directed energy deposition additive manufacturing (DED-AM). 
Type Of Material Database/Collection of data 
Year Produced 2024 
Provided To Others? Yes  
URL https://cord.cranfield.ac.uk/articles/dataset/Knowledge-based_bi-directional_thermal_variable_modell...
 
Title Knowledge-based bi-directional thermal variable modelling for directed energy deposition additive manufacturing (DED-AM) 
Description This dataset is used as the machine learning modelling training dataset in the paper- Knowledge-based bi-directional thermal variable modelling for directed energy deposition additive manufacturing (DED-AM). 
Type Of Material Database/Collection of data 
Year Produced 2024 
Provided To Others? Yes  
URL https://cord.cranfield.ac.uk/articles/dataset/Knowledge-based_bi-directional_thermal_variable_modell...
 
Title Knowledge-based bi-directional thermal variable modelling for directed energy deposition additive manufacturing (DED-AM) 
Description This dataset is used as the machine learning modelling training dataset in the paper- Knowledge-based bi-directional thermal variable modelling for directed energy deposition additive manufacturing (DED-AM). 
Type Of Material Database/Collection of data 
Year Produced 2024 
Provided To Others? Yes  
URL https://cord.cranfield.ac.uk/articles/dataset/Knowledge-based_bi-directional_thermal_variable_modell...
 
Title Process control methods in cold wire gas metal arc additive manufacturing 
Description Data supporting the study published with the name: Process control methods in cold wire gas metal arc additive manufacturing 
Type Of Material Database/Collection of data 
Year Produced 2023 
Provided To Others? Yes  
URL https://cord.cranfield.ac.uk/articles/dataset/Process_control_methods_in_cold_wire_gas_metal_arc_add...
 
Title Remote Ultrasonic Imaging of a Wire Arc Additive Manufactured Ti-6Al-4V Component using Laser Induced Phased Array 
Description Supporting dataset for the publication: "Remote Ultrasonic Imaging of a Wire Arc Additive Manufactured Ti-6Al-4V Component using Laser Induced Phased Array".The file contains all the signals used to produce the images in the paper, using information mentioned in the paper, e.g. pitch and filter centre frequency. 
Type Of Material Database/Collection of data 
Year Produced 2021 
Provided To Others? Yes  
URL https://cord.cranfield.ac.uk/articles/dataset/Remote_Ultrasonic_Imaging_of_a_Wire_Arc_Additive_Manuf...
 
Title Tensile properties and micro hardness of aluminium 2024 wire Directed Energy Deposited material 
Description This file provide the results of mechanicla testing of the 2024 alloy deposited using the wire Directed Energy Deposition process. 
Type Of Material Database/Collection of data 
Year Produced 2023 
Provided To Others? Yes  
URL https://cord.cranfield.ac.uk/articles/dataset/Tensile_properties_and_micro_hardness_of_aluminium_202...
 
Description Manufacture of auxetic structure in FE based shaped memory alloy by wire based AM 
Organisation ETH Zurich
Country Switzerland 
Sector Academic/University 
PI Contribution Testing FE SMA wires, microstructures
Collaborator Contribution provision of wires, deisgn of structures , mechanical testing
Impact 2 x papers
Start Year 2021
 
Description Stainless steel component repair by AM 
Organisation University of Cadiz
Country Spain 
Sector Academic/University 
PI Contribution Training for the PhD student, visiting student to our lab, development of research topic
Collaborator Contribution Resource for this area of research, investigating methods of automated repair including scanning, comparison to CAD and automated toolpath generation, methods for implementing the repair.
Impact None yet
Start Year 2022
 
Description University of Malaysia WAAM collaboration 
Organisation University of Malaysia
Country Malaysia 
Sector Academic/University 
PI Contribution Hosting visit by PhD from University of Malaysia
Collaborator Contribution Student, links to Malaysia industry partners
Impact None yet
Start Year 2023
 
Title Additive manufacture 
Description Method of producing a 3D article by additive manufacture, comprising the steps of; i) forming a meltpool in an already-existing part of the article and moving the meltpool relative thereto; ii) feeding a directed feedstock (which may be a wire or tape) into the moving meltpool to deposit and fuse a layer of material on the already-existing part; and iii) repeating the forming and moving and feeding steps to build up successive layers of material, and thereby produce the 3D article, wherein, in performance of the forming and moving step; a) a first energy source (which may be a plasma transferred arc) is directed onto the already-existing part, the first energy source impinging at a first region which moves with and leads the meltpool, whereby the first energy source initiates the formation of the meltpool and b) a second energy source (which may be one or more lasers) is directed onto the already-existing part, the second energy source impinging at a second region which moves with and follows the first region, whereby the second energy source grows the lateral width of the meltpool before the feedstock is fed therein. A third energy source may be used to melt the feedstock. 
IP Reference GB2569673 
Protection Patent granted
Year Protection Granted 2019
Licensed No
Impact None so far
 
Title Processes for additive manufacture and surface cladding 
Description A gas metal arc welding device can have one or more consumable electrodes 4 delivered to the melt pool at a hot material feed rate; and a non-electrode, supplementary feedstock 10 delivered at a cold material feed rate. A 3D article 6 and/or cladding overlayer can be made; whereby the ratio of the hot material feed rate to the cold material feed rate can be varied during manufacture; e.g., based on sensed temperatures; or in relation to the travel speed of the meltpool. The device may have a gas shroud 3, contact tip 2, arc 5, and controller 11. The deposited bead shape and material microstructure can be kept constant as the article 6 temperature changes. The cold feed 10 may be preheated. High resolution exterior parts of an article can be built slowly while rougher core parts are filled more quickly, in a 'skin and core' approach (figure 7). 
IP Reference GB2601784 
Protection Patent / Patent application
Year Protection Granted 2022
Licensed Yes
Impact This process is currently being implemented into the commercial RoboWAAM system manufactured by WAAM3D
 
Title CW-MIG system 
Description This new technology involves Wire Arc Additive Manufacturing with MIG process as heat source and an additional cold wire. 
Type Of Technology New/Improved Technique/Technology 
Year Produced 2021 
Impact The CW-MIG process offers an extra level of process control, improving the layer height stability in more complex geometries built by WAAM, better microstructure/mechanical properties and less defects. 
 
Title New local shielding device for WAAM 
Description The new local shielding device contains multiple sensors to monitor the WAAM process (image, temperature and layer height). 
Type Of Technology New/Improved Technique/Technology 
Year Produced 2022 
Impact The instrumented shielding device has many benefits: - Avoid oxidation of the deposited material - Quality assurance of (a) material microstructure via temperature control, (b) uniform geometry and no macro defects via layer height control 
 
Title Wire positioning system for WAAM 
Description The new system (software and hardware) is able to self-adjust the position of the cold wire during the WAAM process. The hardware monitors the arc voltage during the WAAM process and, if the wire moves away from the pre-defined position, the software send a signal to the motorised stage holding the wire and corrects its position. 
Type Of Technology Software 
Year Produced 2022 
Impact The new wire positioning system improves stability of metal deposition, improves the quality of the built parts and avoids defects such as lack of fusion. 
 
Company Name WAAM3D 
Description WAAM3D manufactures specialist components using wire-based directed-energy-deposition additive-manufacturing (WAAM). 
Year Established 2018 
Impact WAAM3D has secured £1.5 Million of investment from an overseas investor and is now recruiting to 12 staff (5 so far). It has received it first orders for systems and wire valuing nearly £2 Million already. It has also secured research contract for €300k. The company is currently securing its own premises.
Website http://www.waam3d.com
 
Description 1st NEWAM Open day 
Form Of Engagement Activity Participation in an open day or visit at my research institution
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Several presentations to introduce the NEWAM research programme to the indutrial partners and non-partners. The main goal was to engage with the industry and discuss about the on-going and future collaboration. There was a lot of support offered from the industrial partners who are keen to be involved further in the programme.
Year(s) Of Engagement Activity 2019
 
Description Article in the UK Manufacturing Review (UKMR) 19/20 
Form Of Engagement Activity A magazine, newsletter or online publication
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact This article is about the NEWAM research programme and aims to let the manufacturing community know about the next steps towards the next generation of additive manufacturing.
Year(s) Of Engagement Activity 2020
URL https://ukmfgreview.com/
 
Description Babcock visit 
Form Of Engagement Activity Participation in an open day or visit at my research institution
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact Lab tour and discussion about the current projects
Year(s) Of Engagement Activity 2019
 
Description Brooksward Primary school, Milton Keynes 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Schools
Results and Impact This was an online event with more than 300 pupils engaged in diverse activities (presentations and competition).
The pupils learnt about Additive Manufacturing, applications and its benefits.
Year(s) Of Engagement Activity 2021
URL https://www.facebook.com/BrookswardPrimarySchool/posts/124222179804248
 
Description Business trip to India 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact The trip to India included visiting the following companies:
Velore - Interest in a short course and possibly participating in a project
Tata steel - Sponsoring of 1 PhD student
Fronius - Interested in the WAAM technology
Trinity - Interest in a short course
Year(s) Of Engagement Activity 2020
 
Description Conference talk - ICOTOM 19 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Conference talk "Simulation and Texture" at the 19th International Conference on Textures of Materials (ICOTOM 19)
Virtual conference
Year(s) Of Engagement Activity 2021
URL https://icotom19.com/
 
Description Conference talk and poster presentation at TMS2020 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Conference presentation entitled "Alloy-dilution Effects and Mechanical Response in Wire-arc Additively-manufactured Alloy-alloy Composites Built Using Ti- 6Al-4V and Commercially-pure Titanium."

Poster presentation entitled "Performance of Wire-arc Additive Manufactured Ti-6Al- 4V and Ti-5Al-5Mo-5V-3Cr Dissimilar Alloy-alloy Composite Interfaces."
Year(s) Of Engagement Activity 2020
URL https://www.tms.org/TMS2020
 
Description Conference talk at COM2020 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Conference presentation entitled "Application of Inoculation Methods for Grain Refinement of Wire-Arc Additive Manufactured" at the COM2020 (Conference Of Metallurgists)
Year(s) Of Engagement Activity 2020
URL https://com.metsoc.org/
 
Description Exhibiting at TCT Stars Of The Future Area, NEC 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact The NEWAM stand had many visitors from different sectors (industry, research centres and academia). Most of them were interested in the research programme and a few showed interest in purchasing AM machines from the spinout company (WAAM3D) and starting an MSc course in Cranfield University. The NEWAM stand was the only one showing Wire plus Arc Aditive Manufacturing and large scale AM components and the visitors understood the benefit of this technology.
Year(s) Of Engagement Activity 2019
URL https://www.tctmagazine.com/tct-events/tct-3sixty-uk/new-3d-printing-technologies-tct-show/
 
Description Exhibiting in the National Manufacturing Debate 2019 
Form Of Engagement Activity Participation in an open day or visit at my research institution
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact There was a stand to promote the NEWAM research programme. The main outcome was an invitation to participate in the Advanced Engineering 2019 show - 30 & 31 October 2019, NEC, Birmingham
Year(s) Of Engagement Activity 2019
URL https://www.cranfield.ac.uk/alumni/alumni-events/national-manufacturing-debate-2019
 
Description Experiment demonstrations for public engagement - British Science week 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Public/other audiences
Results and Impact Experiment demonstrations for public engagement - British Science week
Year(s) Of Engagement Activity 2020
URL https://www.britishscienceweek.org/
 
Description Invited lecture in Southampton 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Postgraduate students
Results and Impact Invited lecture on additive manufacture and laser processing. The main goal was to raise the academic awareness of our projects.
Year(s) Of Engagement Activity 2018
 
Description Invited talk in Europhoton 18 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Invited talk on fundamentals of material interaction in laser processing. The main outcome was the promotion of industrial applications within the scientific community.
Year(s) Of Engagement Activity 2018
 
Description Kempston Primary school 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Schools
Results and Impact Pupils from a local school attended the Manufacturing and Materials week 2022 at Cranfield University and the theme of the event was sustainability. Here we had a stand with the plastic 3D printer for demonstration and a microscope showing sample analysis to promote STEM.
Year(s) Of Engagement Activity 2022
 
Description Lab tour for 207 Cranfield Squadron 
Form Of Engagement Activity Participation in an open day or visit at my research institution
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Schools
Results and Impact The 13 to 18 year old puplils visited the laboratory of the welding centre and learn about the most recent research projects on laser processing and additive manufacturing.
Year(s) Of Engagement Activity 2019
 
Description London International Youth Science Forum 
Form Of Engagement Activity Participation in an open day or visit at my research institution
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Schools
Results and Impact Lab tour - Additive Manufacturing facilities
Year(s) Of Engagement Activity 2022
 
Description London International Youth Science Forum (LIYSF) - Lab tour 
Form Of Engagement Activity Participation in an open day or visit at my research institution
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Schools
Results and Impact Cranfield University hosted the London International Youth Science Forum (LIYSF) event. The 16 to 21 year old puplils visited the laboratory of the welding centre and learn about the most recent research projects on laser processing and additive manufacturing.
Year(s) Of Engagement Activity 2019
URL https://www.liysf.org.uk/liysf/scientific-visits/
 
Description London branch TWI joint meeting 
Form Of Engagement Activity Participation in an open day or visit at my research institution
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact Invited lecture on additive manufacture and laser processing
Presentation of the programme and state of the art
Year(s) Of Engagement Activity 2023
 
Description NEWAM and WAAMmat Industry day 2021 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Workshop to disseminate the research outputs of the NEWAM project. There were nearly 70 attendees, including 40 guests from the industry.
Year(s) Of Engagement Activity 2021
URL https://newam.uk/news-events/newam-industry-day-2021
 
Description Participation in MK Innovates 2019 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Schools
Results and Impact This was an outreach event with the purpose to enthuse students towards a career in STEM by showcasing innovative and exciting companies in MK and the surrounding areas, additionally to appeal to adults who may be considering a change of career. The stand had a few large scale AM components and a 3D printer printing funcional parts.
The event was successful with people from different ages interested in the MSc courses and the pupils interested in the technology.
Year(s) Of Engagement Activity 2019
URL https://www.mkinnovates.co.uk/
 
Description Participation in the Advanced Engineering 2019 - NEC 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact The stand had many visitors from different sectors (industry, research centres and academia). Most of them were interested in the research programme and on the MSc courses. The visitors undertood the benefit of using Wire Plus Arc Additive Manufacturing to build large scale components.
Year(s) Of Engagement Activity 2019
URL https://www.thenec.co.uk/whats-on/advanced-engineering/
 
Description Participation in the STEM week at Brooksward school (4-11 year old pupils) 
Form Of Engagement Activity Participation in an open day or visit at my research institution
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Schools
Results and Impact A team of researchers and PhD students working on the NEWAM programme participated in the STEM week organised by Brooksward Primary School in Milton Keynes (4-11 year olds). Approximately 300 children took part of the event. The pupils were shown the concept of additive manufacturing and had a challenge to design and build something that would make the planet a better place. The winners had their models 3D printed to be displayed in their classroom.
The feedback from the head of the school was "It (the event) has really inspired a lot of them (pupils) and some of the feedback I have had from teachers is that it engaged many of the children who aren't often that into design and building and they have started to talk about other things they might want to design." "Also, the children that were chosen to represent the year groups in many cases, were not the children that usually get chosen for things so it was great to see them get a confidence boost."
Year(s) Of Engagement Activity 2021
URL https://www.facebook.com/BrookswardPrimarySchool/posts/124222179804248
 
Description Prenscia Technology Days - virtual seminar series 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact A few members of the NEWAM team presented at a virtual seminar entitled "Prenscia Technology Days" which was organised by one of the NEWAM industrial partnars.
This event was beneficial to disseminate the research outputs in the wide communitity and also to strengthen the link between the collaborating Universitites and Industry.
Year(s) Of Engagement Activity 2021
URL https://www.hbmprenscia.com/about/events/2021-prenscia-technology-days-virtual-seminar-series
 
Description Presentation in ICALEO 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Expression of interest from international companies on the work presented.
Year(s) Of Engagement Activity 2018
 
Description Robert Bloomfield Middle school, Shefford 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Schools
Results and Impact In this event there were talks about Additive Manufacturing and how it is used in different sectors.
Year(s) Of Engagement Activity 2022
URL https://www.facebook.com/RobertBloomfieldAcademy/posts/4771658969569369
 
Description School visit - Bedford Academy 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Schools
Results and Impact The school invited us to participate in their STEM careers fair. We had a stand with various demos: toy robotic arm, plastic 3D printer, humanoid robot, VR welding kit and thermal camera for the pupils to try.
Year(s) Of Engagement Activity 2023
 
Description TeenTech MK - A STEM outreach activity 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Schools
Results and Impact TeenTech run a number of programmes to help young people understand the opportunities in contemporary industry, changing the perceptions of those who may have dismissed them as 'not for me'. The festival activity brought together 30 schools from across the region for a carefully planned day where they took part in challenges with digital, tech, engineering and science companies.
The stand had the following: 3D printer demo, mechanical testing demo, portable microscope, video of the AM process.
At the end of the demo the pupils were asked to think about something that could be 3D printed and to write their ideas on post-its. The best ideas were rewarded with goody bags.
Year(s) Of Engagement Activity 2019
URL https://www.teentech.com/teentech-events/
 
Description Visit to Robert Bloomfield Academy - Electives Feb 2021 - Careers and 3D printing 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach Regional
Primary Audience Schools
Results and Impact The NEWAM team (including academics, researchers, students and administrative staff) visited the Robert Bloomfield Academy to talk about their career paths and 3D printing. The main goal of the visit was to promote the STEM curriculum and encourage the future generation to study STEM subjects.
The pupils were very interested in 3D printing and asked many questions about the subject. The pupils will visit Cranfield University as soon as the Covid-related restrictions are lifted.
Year(s) Of Engagement Activity 2022
 
Description Visit to university by a local school - lab tour - St. Paul School 
Form Of Engagement Activity Participation in an open day or visit at my research institution
Part Of Official Scheme? No
Geographic Reach Regional
Primary Audience Schools
Results and Impact This was a successful event. There was a lab tour and a demonstration with the 3D printer which caught the attention of the pupils and helped them understanding the technology.
Year(s) Of Engagement Activity 2019
 
Description Visitors from Singaporean National Additive Manufacture Centre 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Discussion about future collaboration
Year(s) Of Engagement Activity 2018
 
Description Website - Research progress updates 
Form Of Engagement Activity Engagement focused website, blog or social media channel
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact The website is being constantly updated with the latest research outcomes.
This is route of dissemination can reach different sectors and countries.
Year(s) Of Engagement Activity 2020,2021
URL https://newam.uk/
 
Description Workshop: Manufacturing of Advanced Structural Materials for Transport Systems, India, Vellore Institute of Technology 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Undergraduate students
Results and Impact The two day workshop covered the following: Additive manufacturing, laser processing, advanced joining processes and the NEWAM research programme. The aim was to promote the NEWAM research programme and also the post-graduate courses in Cranfield University. A few undergraduate students are planning to do an MSc in Cranfield University.
Year(s) Of Engagement Activity 2020
URL http://info.vit.ac.in/events-vit/structural-materials/apply.asp