Additive Manufacturing and Welding

Abstract

This chapter addresses the integration of additive manufacturing (AM) and welding technologies, highlighting their synergistic value in prototyping and production for automotive, medical, and aerospace industries. The integration of AM's ability to produce complex geometries with welding's strength, hybrid systems like Wire Arc Additive Manufacturing (WAAM) enable rapid design iteration, material savings, and scalable manufacturing. The research covers fundamental concepts, including AM processes and welding procedures, as well as material issues and integration process problems. Real-world applications demonstrate up to 40% lead time savings and 15–25% weight reduction. Statistical process control and non-destructive testing ensure compliance with standards like ISO/ASTM 52900. However, limitations like thermal management, high costs, and training gaps in the workforce persist.