A pipe spool that measures 850 mm in length and 450 mm in diameter. A critical component used in the oil & gas industry that conforms to stringent industry standards, including American Petroleum Institute (API) Standard 20S. A part, previously fabricated from three pieces welded together, made as a monolithic structure; printed in 216 hours and machined to specification in just 12—less than half the time required for its forged counterpart. A high-pressure pipe spool delivered in just 1.5 weeks, 85% faster than traditional methods, made from a process that generates significantly less waste and consumes less energy. That process? AML3D’s patented WAM technology.

Australian company AML3D has the bold ambition to transform how global industries like oil & gas, defense and maritime think about metal production. Since its founding in 2014, it has progressed steadily in this goal, bringing its WAM process to market through its ARCEMY systems and expanding its reach to new regions. Use cases like the pipe spool—at the time of its production the largest, verified 3D printed oil & gas piping component—illustrate perfectly the impact that AML3D’s technology is having and how it is unlocking more efficient production for critical large-scale metal components.

Breaking down the WAM process

The WAM production process includes several key steps, including print preparation and toolpath planning with WAMSoft, setting hardware operating parameters using AMLSoft, near-net-shape printing on an ARCEMY machine, post-print treatment and finally CNC machining to obtain the final component.

AML3D’s two software programs underpin the company’s industrial AM process. WAMSoft is a slicer and path planning tool into which users upload their CAD models for print preparation. It is in this program that users can choose the type of slicing they want (radial, conical or parallel), and control parameters like multi-stage printing, weld settings, torch angles and more. Crucially, users can simulate the toolpath for a given structure allowing them to identify potential errors before they occur in the print process.

AMLSoft, for its part, communicates the toolpath generated by WAMSoft to the printer and features a host of ARCEMY hardware controls. With a user-friendly interface, AMLSoft enables users to set machine parameters like wire-feed speeds and gas flow, as well as materials parameters and production cell settings. This program also integrates real-time monitoring, giving users the option of manual monitoring or automated data-driven monitoring and decision making.

At the center of the WAM workflow is, of course, the printer hardware. AML3D’s ARCEMY systems are among the largest open-air metal 3D printers on the market, capable of printing metal parts up to 1.8 x 1.8 m (with the potential to go even larger on custom machines). The WAM process that all ARCEMY systems are based on is a DED process that combines an electric arc with certified welding wire feedstock to create near-net-shape parts. The process is also notable for using localized inert gas shielding, which is key to the large-scale, free-form nature of the technology, as it eliminates the need for an enclosed build chamber.

In short, the process works by using the electric arc to melt welding wire and deposit it, layer by layer, onto a base, where it cools and hardens. After the printing is complete, a solid, near-net-shape part remains, which is then ready to undergo post-processing steps, such as optional heat treatments or overlays to improve material properties, as well as CNC machining to achieve tight tolerances and a smooth surface finish.

Also worth noting is that AML3D’s solutions are compatible with a wide range of materials, such as titanium, copper, steel, stainless steel and nickel alloys, as well as exotic metals. This material diversity—far wider than other metal AM processes—is possible because the WAM process consumes certified welding wire feedstocks, which are readily available and easier to work with than AM powders (not to mention cheaper).

A host of benefits: faster, greener, stronger

Now that we’ve covered the steps involved in producing metal components using AML3D’s WAM process, it’s time to look at the advantages this technology offers over more conventional metal production approaches like machining billet, forging and casting.

Firstly, AML3D’s process can dramatically accelerate the turnaround time for a part from concept to deployment. As we saw with the 3D printed pipe spool, a time saving of 85% was attained, with the large-scale part requiring only 216 hours of printing (the equivalent of nine days) and 12 hours of machining. This acceleration is the result of a couple of factors, including rapid deposition rates facilitated by sophisticated wire feeding and welding systems; the ability to consolidate parts (e.g. the pipe spool was consolidated from three sections into a monolithic structure); and the agile nature of the technology, which can directly produce high-quality metal components without the need for tooling.

The WAM process is also more ecological than traditional metal manufacturing processes. This is driven in part by a reduction in material waste resulting from the additive nature of the process and the creation of near-net-shape parts. In the case of the pipe stool, for instance, the part had a deposited mass of 1,120 kg and a final machined mass of 940 kg, making for a relatively low buy-to-fly ratio. AML3D’s solution is also less energy intensive than other metal AM processes, like LPBF and EBM, due to its high deposition rates and use of an electric arc. Moreover, the WAM process is suited to the repair of existing metal structures, which can extend the lifespan of older parts—always an environmental plus.

Not only does AML3D’s technology enable manufacturers in energy, defense, maritime and other industries to speed up production and improve their carbon footprint, it also makes dense metal parts that are stronger than their forged counterparts. In a third-party test, steel components 3D printed using AML3D’s WAM process had a 10% higher ultimate tensile strength (UTS) compared to forged parts and a 30% higher UTS than the applicable global standard. AML3D has also compared Nickel Aluminum Bronze components and found its printed parts had up to 50% greater fatigue resistance.

Growing global recognition

It is no surprise that a solution that offers faster, greener and stronger production for large-scale metal parts has caught the attention of industrial players around the world. AML3D has done well to capitalize on this interest, scaling up its operations in the United States, United Kingdom and Europe, with a particular focus on defense and maritime applications.

In July, for instance, AML3D sold one of its ARCEMY platforms to Austal USA, which will be deployed at the US Navy’s Additive Manufacturing Center of Excellence. Even more recently, the company sold two custom ARCEMY X systems, with a weight capacity of 10,886 kg each, to North America’s largest military shipbuilder, HII Newport News. The company will also be working with the US Navy to support its Maritime Industrial Base through material characterization and parts manufacturing. In Europe, the company has been growing its distribution network with partnerships with Arc Additive Limited and DMFG Solutions GmbH. It’s therefore clear that WAM technology is gaining a real foothold and is very much changing how metal parts are made.

This article was originally published in VoxelMatters’ VM Focus Metal AM eBook. Read or download the full eBook for free at this link.