Investigation of complex single-walled intersecting structures fabricated by wire-arc directed energy deposition

Purpose: This study aims to investigate an intersecting single-walled structure fabricated using wire-arc directed energy deposition (waDED). Because of the highly complex geometrical features of this structure, characterisation is used to identify potential weak points and provide a benchmark for future complex components. Design/methodology/approach: A structural component with a process-specific design is built using additive manufacturing of an Al-Mg alloy and analysed using micro-computed tomography. Scans are carried out at different resolutions and subsequently compared to microsections. The chemical composition and hardness are also examined. These investigations provide an enhanced understanding of defects and overall quality of the manufactured parts. Findings: The results show that very high-quality parts can be achieved using ER5183 alloy, even in intersecting areas. Defects in these regions are primarily caused by converging and diverging waDED paths and discontinuous waDED operations. Originality/value: In addition to demonstrating the feasibility of complex structures using waDED, this study provides an overview of problem areas and potential improvements in waDED manufacturing.