Design and development of a metal additive manufacturing system using metal inert gas (MIG) technology

Abstract

Metal Additive Manufacturing (AM) has advanced significantly due to its ability to fabricate complex geometries with reduced waste and lead time, proving economic viability compared to conventional manufacturing methods [1]. Among metal AM technologies, Wire Arc Additive Manufacturing (WAAM) is particularly suited for large-scale components, leveraging the arc welding process for high deposition rates. WAAM is cost-effective due to its use of inexpensive welding wire and standard equipment. Gas Metal Arc Welding (GMAW), a widely used WAAM technology, uses an electric arc to melt a continuously fed wire, depositing material layer by layer under shielding gas. It is classified as Metal Inert Gas (MIG) and Metal Active Gas (MAG) depending on the type of shielding gas used. However, its main limitations include reduced dimensional accuracy, difficulties in fabricating complex geometries, and the need for extensive post-processing [2]. The primary objective of this study is to develop a lowcost metal AM system that incorporates a readily available welding technology, MIG, thereby offering small-scale manufacturers and developing nations an alternative solution for fabricating and repairing complex metallic components.