A Complete Study on Various Area Filling Strategies Used in Weld Deposition-Based Additive Manufacturing

Abstract

Achieving the optimal toolpath as well as obtaining the desired physical and geometrical properties for bulk metallic parts through weld deposition-based additive manufacturing (AM) is a challenging task. The current work aims in identifying the suitable toolpath for bulk weld deposition-based AM applications by comparing the various toolpath (eleven types) techniques. These toolpaths were evaluated based on the final layer thickness attained after face milling (skinning) operation, minimum amount material machined during the face milling, average hardness achieved, length of the heat-affected zone (HAZ) and the microstructural behaviour. Amongst the various toolpath patterns considered, hybrid toolpath (Single Contour Out with Hilbert In) is ideal for bulk deposition-based AM owing to its maximum final layer thickness and the minimum amount of material removed in skinning operation. On the other hand, it has been observed that Spiral Out to In toolpath pattern is inferior for bulk deposition-based AM. Additionally, the average grain size is presented for some of the toolpath patterns in the current article.