We were able to complete our first research project (FKZ: ZF4760001FH9) entitled rebars-print in January 2022. The aim with the TU Dresden was the production of reinforcements for the construction industry by means of MIG/MAG welding, in which droplet-wise welding filler material is built up. This process is also called WAAM – the abbreviation for Wire Arc Additive Manufacturing.
The optimization of the welding process was the focus of the professorship for joining technology at TU Dresden. Currently, heavy metal base structures must be used, which serve as a welding base and cool the weld metal. Subsequently, the weld drop shapes must be separated with an angle grinder. In order to weld economically, the separation process would have to be avoided and the expensive base material dispensed with. However, the attempt to weld on sand failed. Alternatively, it would have been sufficient to be able to break off the WAAM reinforcement, at least with little effort. This approach also failed in the project.
Grötschel GmbH was working in parallel on a modular system to categorize objects in the construction industry and divide them into small elements that fit into the working area of an industrial robot. Such a division into two main groups is possible. The small elements must then be joined together to form building-sized reinforcements. We have dealt intensively with this topic, developed solutions, established contacts with engineering offices and architects, and actively searched for suitable applications.
Since the mechanical properties of the WAAM reinforcement fluctuated greatly, we also looked for alternatives on the process side. We found a solution in Klipphausen at OSCAR-PLT. With the experience from this project, we can process a project with approval in individual cases.
