Pragana, JoãoBragança, I. M. FSilva, C. M. A.Martins, P. A. F.2023-02-142023-02-142022-04PRAGANA, J. P. M.; [et al] – Hybrid wire-arc additive manufacturing of conformal cooling channels: A feasibility study. International Journal of Precision Engineering and Manufacturing-Green Technology. ISSN 2288-6206. Vol. 10, N.º 1 (2023) pp. 45–57.2288-6206http://hdl.handle.net/10400.21/15596This paper investigates the feasibility of hybridizing wire-arc additive manufacturing with metal forming to create conformal cooling channels in moulds for hot material processing. An axisymmetric mould is used as a prototype test case and plastic deformation by flaring of the additively deposited inner tubular element is utilized to create the overhangs for connecting with the outer tubular element that are needed to fabricate the cooling channels. Finite element modelling of plastic deformation by flaring of the additively deposited material is carried out to identify the different modes of deformation and to determine the maximum allowable radius of the overhangs. Results show that the proposed hybridization of wire-arc additive manufacturing with plastic deformation by flaring adds flexibility to the design and fabrication of conformal channels in the as-built mould by eliminating the use of support structures and avoiding the use of complex deposition strategies. Finishing of the functional surfaces of the as-built mould by turning ensures the required accuracy and surface quality.engDies and mouldsConformal channelsHybrid wire-arc additive manufacturingMetal formingExperimentationFinite element methodjournal article10.1007/s40684-022-00436-w2198-0810