Klötzer-Freese, ChristianChristianKlötzer-FreeseKruse, TobiasTobiasKruseKhalil, MohamadMohamadKhalilGreitsch, LarsLarsGreitsch2024-04-112024-04-112024-04-048th International Symposium on Marine Propulsors (smp 2024)978-82-691120-5-4https://hdl.handle.net/11420/46497The development of new manufacturing technologies is opening new prospects to produce components of maritime systems. Particularly in the production of ship propellers with small diameters (D < 5 m), the established sand-casting process can only be used competitively to some extent as a technology in today's market. Additive manufacturing technologies have not only developed rapidly due to their ability to produce near-net-shape components with complex geometry, but also offer various advantages over conventional processes in the area of individual component production. In addition to the geometry and design freedoms, production times, material consumption and, as a result, costs can be reduced enormously for small batch sizes. Ship propellers in the superyacht sector combine the restrictions of the conventional sand-casting process and the potentials of additive manufacturing. A propeller with four blades and a hollow blade structure is being developed as part of a research project. Together with Fraunhofer IGP and the University of Rostock, investigations were carried out into the WAAM process using copper-based alloys. In addition to the conventional pulsed arc process, the Cold Metal Transfer (CMT) process was used to investigate the three welding filler materials CuAl8Ni2Fe2Mn2, CuAl9Ni5Fe3Mn2 and CuMn13Al8Fe3Ni2. Results for a material and process characterization are shown based on buildup welds in the form of wall-shaped structures. Sensitive component areas were then selected to determine process variables for additive and subtractive manufacturing as part of the process development. Testing of different buildup strategies as well as different milling tools is also part of the investigations. To ensure a reduced core drop load on the hollow structure, there is a continuous alternation between buildup welding and milling, both on the external and internal surfaces. A techno-economic comparison between the manufacture of the demonstrator propeller using the WAAM process and sand casting is presented in conclusion.enhttp://rightsstatements.org/vocab/InC/1.0/Additive manufacturingwire arc additive manufacturing WAAMmechanical testingpath planningEngineering and Applied OperationsConference Paper10.15480/882.936010.15480/882.936010.15480/882.9294Conference Paper