Avaliação do diâmetro do arame e trajetória de fabricação de aerofólios de alumínio por manufatura aditiva por deposição a arco

Abstract

Wire Arc Additive Manufacturing (WAAM) has emerged as a promising alternative for producing large metallic components, offering high deposition rates, geometric flexibility, and reduced operational costs when compared to other metal additive manufacturing processes. However, the use of WAAM with aluminum alloys poses significant challenges due to the material’s high thermal conductivity, rapid oxide formation, and susceptibility to arc instability. This study aimed to evaluate the influence of wire diameter and deposition trajectory on the fabrication of ER4043 aluminum airfoils prototypes using WAAM, examining welding parameters, arc behavior, and geometric accuracy. Aluminum wires with diameters of 1.2 mm, 1.0 mm, and 0.8 mm were tested through multilayer wall fabrication and qualitative analyses of continuity, stability, and thermal behavior. Subsequently, different trajectory strategies were developed and applied to a NACA 2412 airfoil, including contour segmentation and local adjustment of robotic travel speed. The results showed that the 1.2 mm wire provided the most stable and reproducible deposition conditions, whereas the 0.8 mm wire proved unfeasible under the tested parameters. Trajectory optimization revealed that controlled variation of travel speed is essential to compensate for geometric curvature differences along the airfoil, resulting in improved dimensional uniformity. The final enlarged prototype exhibited good layer adhesion and a contour consistent with the theoretical model. Overall, the findings demonstrate that wire diameter selection and trajectory definition play a decisive role in the quality of aluminum components produced by WAAM, supporting the advancement of this technique for aerospace and industrial applications.