Design optimisation for hybrid metal additive manufacturing for sustainable construction

verfasst von

Mohammad Hassan Baqershahi, Can Ayas, Elyas Ghafoori

Abstract

Wire arc additive manufacturing (WAAM) enables the manufacturing of efficient and lightweight structural elements in which material can be utilised wherever needed in an optimised shape, in contrast to standard prismatic profiles used in construction. However, the specific energy consumption (SEC) of WAAM is higher than that of conventional manufacturing (CM) techniques (i.e., hot-rolling) for standard profiles. Therefore, it is an open question whether the material savings through computational design realised via WAAM is environmentally beneficial or not. This systematic study aims to provide a better understanding of the environmental impact of hybrid manufacturing, which is defined as the combination of WAAM and CM rather than using any of them alone. Topology optimisation (TO) is used to design a series of beams with an identical performance (i.e., stiffness) but with a reduced material consumption depending on the hybrid ratio. The environmental impact of the designs has been used to determine when and how hybridisation can become advantageous. The results show that although the optimal proportions of WAAM and CM are dependent on their relative SEC, the hybrid solutions have always been environmentally superior compared to that of WAAM or CM alone for the realistic SEC values, exhibiting up to a 60% reduction in environmental impact compared to that of CM.

Organisationseinheit(en)

Institut für Stahlbau

Externe Organisation(en)

Delft University of Technology

Typ

Artikel

Journal

Engineering structures

Band

301

Anzahl der Seiten

12

ISSN

0141-0296

Publikationsdatum

15.02.2024

Publikationsstatus

Veröffentlicht

Peer-reviewed

Ja

ASJC Scopus Sachgebiete

Tief- und Ingenieurbau

Ziele für nachhaltige Entwicklung

SDG 7 – Erschwingliche und saubere Energie

Elektronische Version(en)

https://doi.org/10.1016/j.engstruct.2023.117355 (Zugang: Geschlossen)