Filler wire deflection control for Wire and Arc Additive Manufacturing

Abstract

This paper examines the issue of wire deflection in Wire and Arc Additive Manufacturing (WAAM), which leads to process instability and defects in printed geometry. The study focuses on the deflection of Alloy 601/625, Inconel 718 and SG2 wires during the deposition process. Measurements were taken to determine the relationship between wire deflection and the amount of wire used. Regression models were developed for each material to predict initial wire deflection and changes in deflection due to contact tip wear. The results showed that the deflection of Alloy 601/625 and Inconel 718 wires followed a non-linear pattern for the first 500 meters of wire, while the deflection of SG2 wire followed a nearly linear trend. The intensity of the contact tip wear is dependent on the normal contact load, which decreases as the wear increases. Based on these models, an algorithm was developed to correct the wire deflection by adjusting the tool center point coordinates. The effectiveness of the developed algorithm was verified in practice.