TECHNOLOGY

The use of new methods in production is increasing!

WIRE ARC ADDITIVE MANUFACTURING (WAAM)

Wire arc additive manufacturing (WAAM) is one of the most promising technologies for large-scale part production. WAAM is an additive manufacturing (AM) method that uses an arc as a heat source and a wire as a feed material. In wire arc additive manufacturing, it is possible to perform layered production by using gas metal arc welding, gas tungsten arc welding (GTAW) and plasma arc welding.
WAAM technology is an interesting and low-cost method for the rapid production of medium- and large-scale parts and structures.

Gas Tungsten Arc Welding (GTAW) is the manufacturing technology used by Alloy Additive.

Our engineering team, with expertise in WAAM process and metallurgy, provides advice on the feasibility of manufacturing your desired part through 3D printing and also offers support on the design for manufacturability.

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WAAM OFFERS MANY ADVANTAGES

REDUCTION OF LEAD TIME

On-demand manufacturing without molding, raw material or tooling

REDUCTION OF COST

Low buy-to-fly ratio, production without expensive tooling

VARIETY OF SPECIAL MATERIALs

Printing capability of corrosion-resistant materials such as stainless steels, nickel, titanium, aluminium alloys

DIGITALIZED WAREHOUSE

Storing data instead of parts and manufacturing whenever needed

SYSTEM

ALLOY ADDITIVE PRINTING SYSTEM

Alloy Additive Printing System, which integrates with hardware components of well-known manufacturers worldwide, provides services to its customers by combining with the software developed in-house. Instead of multiple production processes, this system enables the production of large-scale complex geometries by stacking metal layers on top of each other, instant melting and simultaneous solidification.

PROCESS MONITORING AND CONTROL

Process parameters can be tracked and saved via graphical user interface.

Wire speed, arc current, arc voltage and layer temperature are main parameters of WAAM process.

PROJECT

CASE STUDIES

Axle Box Cover – STEEL

Wire Material: AWS/ASME SFA - 5.18 – ER70S-6
Wire Size (mm) : 1.6
Print Mass (kgs) : 21.6
Print Time (h) : 24
Total Part Mass (kgs) : 25.8
Machined Mass (kgs) : 14.6

Spring Mounting Pad ALUMINIUM

Wire Material: AWS/ASME SFA - 5.10 - ER5356
Wire Size (mm) : 1.6
Print Mass (kgs) : 1
Print Time (h) : 2
Total Part Mass (kgs) : 9.17
Machined Mass (kgs) : 3.3

Ti64 Test Block – TITANIUM

Wire Material: AWS A5.16: ERTi-5
Wire Size (mm) : 1.6
Print Mass (kgs) : 0.8
Print Time (h) : 1

Test Block – uNALLOYED STEEL

Wire Material: AWS/ASME SFA - 5.18 – ER70S-6
Wire Size (mm) : 1.6
Print Mass (kgs) : 1.3
Print Time (h) : 1

Gas Turbine Transition Piece – STEEL

Wire Material: AWS/ASME SFA - 5.18 – ER70S-6
Wire Size (mm) : 1.6
Print Mass (kgs) :13 
Print Time (h) : 21 
Height (mm): 225 
Diameter (mm): 432 max.

This downscaled version of liner part of a gas turbine have various processes with high lead time. Firstly, symmetric sheet parts are formed in press system then welded together. After that, boss part is machined from solid block. Finally, boss part is welded to the liner. To simplify this production, we printed the liner than the boss onto liner with the help of workpiece positioner.

Conventional Process:

3 parts, 7 process,

25 days of manufacturing

PARTNERS

SERVICES

DISCOVER ALL THE SERVICES OF ALLOY ADDITIVE

PRINT ON DEMAND

The biggest innovation is that the welding technology can be used in the manufacture of the whole part, instead of using it only in joining. In the WAAM technology used by Alloy Additive, the design file is sliced with the appropriate software and then printed layer by layer. The process gradually transforms the material into a complete 3D object.

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PART REPAIR

In many leading industrial sectors, there are situations where repair or refurbishment can be very advantageous for materials that are damaged or worn during their service life due to their high value in terms of production costs. Repairing metallic parts extends the service life of the part, limiting the waste of energy and material in production industry.

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MATERIALS

As an innovative additive manufacturing company for metals, Alloy Additive Corp. serves with parts made of alloys on the following materials list. Those alloys fulfill the extreme material requirements in defence, aerospace, energy, and oil-gas industries by means of quick solidification during printing process, which leads to refined grain formation in the microstructure and yields high strength values as well as high elongation.

ALLOY ADDITIVE MATERIALS LIST

INDUSTRIES

ALLOY ADDITIVE PROVIDES SERVICES to MULTIPLE INDUSTRIES

AEROSPACE

The Wire Arc Additive Manufacturing (WAAM) method can be used to produce complex metal parts needed in a variety of aerospace industry applications. In addition, more functional, lighter and more economical parts are produced with the WAAM method. The aerospace industry heavily relies on titanium materials due to their exceptional strength-to-weight ratio and corrosion resistance.

OIL & GAS

Since it is important to reduce interruptions in production in the oil and gas sector, the WAAM process which offers short delivery times is preferred.

MARINE

WAAM technology can be used to manufacture complex metal parts required for ships, offshore structures, and marine equipment. The benefits of using WAAM in the marine industry include faster production times, reduced costs, and useage of corrosion resistant metals.

ALLOY ADDITIVE

ABOUT US

Alloy Additive aims to produce perfect designs without limits. Manufacture of large-scale parts (1 meter diameter, 1.5 meter height) through 3D metal printers with the ability to print various types of alloys (Stainless Steel, Ti64, Inconel625, Aluminum alloys).

Wire arc additive manufacturing (WAAM) is the method used in Alloy Additive.

Alloy Additive has participated in 20 Campus Deep Technology Programs of KWORKS.

Alloy Additive office is located in Teknopark Istanbul. Teknopark Istanbul is one of the ecosystems where universities, research institutions, and industrial organizations carry out research, development, and innovation activities in the same environment; transfer information and technology between each other.

Alloy Additive is a member of the ISTANBUL Defense and Aviation Cluster Association (SAHA).

Alloy Additive develops 3D metal printing system within the scope of TÜBİTAK 1501 Industry R&D Projects Support Program.