A Comparative Study of Two WAAM Patterns for Structures with Grid Fin Characteristics

Xian Guo, Jingbang Pan, Qingshan Li

Research output: Contribution to journalArticlepeer-review

Abstract

As a critical component of rocket systems, the grid fin is widely applied in the aerospace industry. Compared to traditional manufacturing methods and other additive manufacturing (AM) techniques, wire arc additive manufacturing (WAAM) is more advantageous in its time and cost efficiency, especially when it is utilized in the large-scale production of components. Given the significant effect of the welding strategies on the quality of manufactured parts, we investigated two distinct WAAM printing orientations, horizontal, or lie (L), and perpendicular, or stand (S), using a small-scale model. The feasibility of these two printing approaches was evaluated by analyzing the surface quality, microstructure, and mechanical properties at the junctions of the grid fin. Furthermore, a finite element analysis (FEA) was adopted to simulate and analyze the main factors, including the temperature distribution, deformation, and stress profiles at the welding joints, in both AM strategies. The integrated approach adopted in this study provides important insights for optimizing the application of WAAM in grid fin manufacturing. In summary, our results indicate that while the L mode is easily manufacturable and exhibits stable properties, the S mode holds significant market potential if its welding parameters are optimized.
Original languageEnglish
Article number219
JournalMaterials
Volume18
Issue number2
Early online date7 Jan 2025
DOIs
Publication statusPublished - 7 Jan 2025

Data Availability Statement

The raw data supporting the conclusions of this article will be made available by the authors on request the rocket company secrets.

Funding

This work was supported in part by the Huzhou Science and Technology Bureau Project (2023GZ08).

Keywords

  • WAAM pattern
  • grid fin
  • microstructure
  • printability
  • residual stress

ASJC Scopus subject areas

  • General Materials Science
  • Condensed Matter Physics

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