A novel method of bead modeling and control for wire and arc additive manufacturing

Abstract

Purpose Modeling and control of bead geometry in wire and arc additive manufacturing is significant as it affects the whole manufacturing process. The purpose of this paper is to establish an efficient model to control the bead geometry with fewer experiments in wire and arc additive manufacturing (WAAM). Design/methodology/approach A multi-sensor system is established to monitor the process parameters and measure the bead geometry information. A dynamic parameters experimental method is proposed for rapid modeling without dozens of experiments. A deep learning method is used for bead modeling and control. To adaptively control the bead geometry in real-time, a closed-loop control system was developed based on the bead model and in situ monitoring. Findings A series of experiments were conducted to train, test and verify the feasibility of the method and system, and the results showed that the proposed method can build the bead model rapidly with high precision, and the closed-loop system can control the forming geometry adaptively. Originality/value The proposed modeling method is novel as the experiment number is reduced. The dynamic parameters experimental method is effective with high precision. The closed-loop control system can control the bead geometry in real-time. The forming accuracy is elevated.

Features of Filler Wire Melting and Transferring in Wire-Arc Additive Manufacturing of Metal Workpieces

“…As welding tool travel speed increases, humping starts to take place. Tang et al [ 20 ] have created an effective model for controlling bead geometry. A deep learning method was used to control the beads.…”

Microstructural Evolution of AA5154 Layers Intermixed with Mo Powder during Electron Beam Wire-Feed Additive Manufacturing (EBAM)

“…Additive manufacturing methods used for making metallic components include wire arc additive manufacturing (WAAM) [21][22][23][24][25], selective laser melting (SLM) [26][27][28] and electron beam additive manufacturing (EBAM) [29][30][31][32]. These methods have their own advantages and disadvantages but the majority of experiments on making aluminum alloy matrix composites were carried out using these three.…”

The Effect of a Slow Strain Rate on the Stress Corrosion Resistance of Austenitic Stainless Steel Produced by the Wire Laser Additive Manufacturing Process

“…Therefore, alternative AM technologies such as direct energy deposition processes have been developed recently [15][16][17][18]. Some of these direct energy deposition processes use wires as raw materials instead of powders [19][20][21][22][23][24][25][26]. Apart from the significantly reduced cost of wire (compared with powder), wire additive manufacturing processes enable deposition rates of up to 3 kg/h to be reached, compared with only 0.1 kg/h by PBF processes [27,28].…”