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<p>Typically fabricated through laser-based powder bed fusion (PBF-LB), metal strut-based lattice metamaterials are valued for their low density, high strength-to-weight ratio, thermal efficiency, and energy absorption, making them suitable for demanding applications. However, these PBF-LB lattices are limited to the size constraints of the powder bed fusion system, which is often less than 1&#xa0;m. Wire arc additive manufacturing (WAAM) is a recent development that may offer a solution using digital metal droplets. However, the manufacturability constraints have not yet been systematically determined. This study investigates the first WAAM manufacturability analysis of nickel aluminium bronze (NAB) lattice struts under varying wire feed speeds (WFS) and inclination angle (<i>θ</i>). A total of 32 struts were manufactured and duplicated to assess reproducibility. Through both geometric and microstructural characterisation of the lattice struts’ internal and external profile, the results show that a WFS of 7&#xa0;m/min yielded the highest build quality across all inclination angles based on a criterion including success rate, elongation, circularity, and relative straightness. Furthermore, a multivariable linear model was developed using Ridge regression to predict strut diameter as a function of WFS and <i>θ</i>. The findings provide foundational insights for future WAAM fabrication of NAB lattice structures. Particularly, face-centred cubic unit cell topologies with and without axial struts are considered feasible for reliable production using the optimised parameters.</p>

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Manufacturability of nickel aluminium bronze lattice struts via digital metal droplet wire arc additive manufacturing

  • 期刊论文

  • 发表日期：

    2026年1月8日

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  • Jiayu Ye,
  • Jordan Noronha,
  • Philip Pille,
  • Cameron Barr,
  • Ethan Haberl,
  • Martin Leary,
  • Ma Qian,
  • Andrey Molotnikov,
  • Milan Brandt

摘要

Typically fabricated through laser-based powder bed fusion (PBF-LB), metal strut-based lattice metamaterials are valued for their low density, high strength-to-weight ratio, thermal efficiency, and energy absorption, making them suitable for demanding applications. However, these PBF-LB lattices are limited to the size constraints of the powder bed fusion system, which is often less than 1 m. Wire arc additive manufacturing (WAAM) is a recent development that may offer a solution using digital metal droplets. However, the manufacturability constraints have not yet been systematically determined. This study investigates the first WAAM manufacturability analysis of nickel aluminium bronze (NAB) lattice struts under varying wire feed speeds (WFS) and inclination angle (θ). A total of 32 struts were manufactured and duplicated to assess reproducibility. Through both geometric and microstructural characterisation of the lattice struts’ internal and external profile, the results show that a WFS of 7 m/min yielded the highest build quality across all inclination angles based on a criterion including success rate, elongation, circularity, and relative straightness. Furthermore, a multivariable linear model was developed using Ridge regression to predict strut diameter as a function of WFS and θ. The findings provide foundational insights for future WAAM fabrication of NAB lattice structures. Particularly, face-centred cubic unit cell topologies with and without axial struts are considered feasible for reliable production using the optimised parameters.