Post by GEFERTEC

The bellmouth intake: WAAM Is Not Welding Repeated - It Is Manufacturing Reimagined WAAM is often associated with welding, but this application shows something very different: the arc is not being used to join existing parts - it is being used to manufacture a fully functional metal component layer by layer within a controlled and qualified production process. For this bellmouth intake used in a pressure-device application, the objective was not only to produce a large stainless steel part, but to establish a validated manufacturing route for it. The component was approved according to AD 2000, and the implementation of 3DMP® WAAM included a welding procedure qualification in accordance with DIN EN ISO 15614-1:2017-12 (Level 2). Comparative samples were produced first, followed by destructive material testing and final production using validated process parameters. This type of component can be realized within our arc machine portfolio, depending on the specific application requirements and production setup. For this bellmouth intake, 316L wire with a diameter of 1.2 mm was used. The geometry measured Ø 850–650 x 315 mm, with a print mass of 170 kg and a build time of 45 hours, including cooling time. The process was monitored using the 3DMP® Quality Manager to provide the level of control required for an industrial application of this kind. What makes this case especially relevant is the comparison to conventional manufacturing. Producing the part by machining from solid material would have required a starting blank of around 1.6 tons. With WAAM, the near-net-shape blank was reduced to 240 kg, resulting in 70% lower material costs and a 60% reduction in delivery time. For large metal components like this, WAAM is more than an alternative production method. It shortens the process chain, reduces dependence on semi-finished stock, and allows design changes much later in the production timeline. That combination of qualification, material efficiency, and manufacturing flexibility is where additive manufacturing creates measurable industrial value.

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