Mapping of Bead Geometry in Wire Arc Additive Manufacturing Systems Using Passive Vision

2022 ◽  
Author(s):  
Marcus O. Couto ◽  
Arthur G. Rodrigues ◽  
Fernando Coutinho ◽  
Ramon R. Costa ◽  
Antonio C. Leite ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Systems ◽  
Bead Geometry ◽  
Wire Arc Additive Manufacturing

Control of humping phenomenon and analyzing mechanical properties of Al–Si wire-arc additive manufacturing fabricated samples using cold metal transfer process

2021 ◽  
pp. 095440622199840
Author(s):  
Yashwant Koli ◽  
N Yuvaraj ◽  
Aravindan Sivanandam ◽  
Vipin
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Heat Input ◽  
Large Scale ◽  
High Deposition Rate ◽  
Bead Geometry ◽  
Layer By Layer ◽  
Cold Metal Transfer ◽  
Geometrical Shapes ◽  
Wire Arc Additive Manufacturing

Nowadays, rapid prototyping is an emerging trend that is followed by industries and auto sector on a large scale which produces intricate geometrical shapes for industrial applications. The wire arc additive manufacturing (WAAM) technique produces large scale industrial products which having intricate geometrical shapes, which is fabricated by layer by layer metal deposition. In this paper, the CMT technique is used to fabricate single-walled WAAM samples. CMT has a high deposition rate, lower thermal heat input and high cladding efficiency characteristics. Humping is a common defect encountered in the WAAM method which not only deteriorates the bead geometry/weld aesthetics but also limits the positional capability in the process. Humping defect also plays a vital role in the reduction of hardness and tensile strength of the fabricated WAAM sample. The humping defect can be controlled by using low heat input parameters which ultimately improves the mechanical properties of WAAM samples. Two types of path planning directions namely uni-directional and bi-directional are adopted in this paper. Results show that the optimum WAAM sample can be achieved by adopting a bi-directional strategy and operating with lower heat input process parameters. This avoids both material wastage and humping defect of the fabricated samples.

Wire arc additive manufacturing of Invar parts: bead geometry and melt pool monitoring

Measurement ◽  
2021 ◽  
pp. 110452
Author(s):  
Fernando Veiga ◽  
Alfredo Suarez ◽  
Eider Aldalur ◽  
Teresa Artaza
Keyword(s):  
Additive Manufacturing ◽  
Bead Geometry ◽  
Melt Pool ◽  
Wire Arc Additive Manufacturing

Using Unsupervised Learning for Regulating Deposition Speed During Robotic Wire Arc Additive Manufacturing

2021 ◽  
Author(s):  
Ashish Kulkarni ◽  
Prahar M. Bhatt ◽  
Alec Kanyuck ◽  
Satyandra K. Gupta
Keyword(s):  
Additive Manufacturing ◽  
Unsupervised Learning ◽  
Molten Metal ◽  
Length Variation ◽  
Bead Geometry ◽  
Layer By Layer ◽  
Arc Length ◽  
Regulation Scheme ◽  
Speed Regulation ◽  
Wire Arc Additive Manufacturing

Abstract Robotic Wire Arc Additive Manufacturing (WAAM) is the layer-by-layer deposition of molten metal to build a three-dimensional part. In this process, the fed metal wire is melted using an electric arc as a heat source. The process is sensitive to the arc conditions, such as arc length. While building WAAM parts, the metal beads overlap at corners causing material accumulation. Material accumulation is undesirable as it leads to uneven build height and process failures caused by arc length variation. This paper introduces a deposition speed regulation scheme to avoid the corner accumulation problem and build parts with uniform build height. The regulated speed has a complex relationship with the corner angle, bead geometry, and molten metal dynamics. So we need to train a model that can predict suitable speed regulations for corner angles encountered while building the part. We develop an unsupervised learning technique to characterize the uniformity of the bead profile of a WAAM built layer and check for anomalous bead profiles. We train a model using these results that can predict suitable speed regulation parameters for different corner angles. We test this model by building a WAAM part using our speed regulation scheme and validate if the built part has uniform build height and reduced corner defects.

scholarly journals Evaluation of Bead Geometry for Aluminum Parts Fabricated Using Additive Manufacturing-Based Wire-Arc Welding

Processes ◽  
2020 ◽  
Vol 8 (10) ◽  
pp. 1211
Author(s):  
Hee-keun Lee ◽  
Jisun Kim ◽  
Changmin Pyo ◽  
Jaewoong Kim
Keyword(s):  
Additive Manufacturing ◽  
Heat Input ◽  
Deposition Efficiency ◽  
Bead Geometry ◽  
Thin Wall ◽  
Cross Sectional ◽  
Voltage Ratio ◽  
Input Range ◽  
The Cross ◽  
Wire Arc Additive Manufacturing

The wire arc additive manufacturing (WAAM) process used to manufacture aluminum parts has a number of variables. This study focuses on the effects of the heat input and the current and voltage ratio on the deposition efficiency. The effects of the heat input and current and voltage ratio (V/A) on the bead geometry were analyzed, depending on the cross-sectional geometry of the deposition layers, for nine different deposition conditions. The deposition efficiency was also analyzed by analyzing the cross-sectional geometry of the thin-wall parts made of aluminum. The heat input range was about 2.7 kJ/cm to 4.5 kJ/cm; the higher the heat input, the higher the deposition efficiency. The maximum deposition efficiency achieved in this study was 76%. The current and voltage ratio was used to quantify the portion of voltage (V) in the total heat input (Q), and the effect on the bead geometry was analyzed. As the portion of voltage in the quasi heat input decreased by about 10%, it was found that the deposition efficiency was decreased by 1% to 3%.

scholarly journals Effect of the Metal Transfer Mode on the Symmetry of Bead Geometry in WAAM Aluminum

Symmetry ◽  
2021 ◽  
Vol 13 (7) ◽  
pp. 1245
Author(s):  
Fernando Veiga ◽  
Alfredo Suárez ◽  
Eider Aldalur ◽  
Trunal Bhujangrao
Keyword(s):  
Additive Manufacturing ◽  
Gas Metal Arc Welding ◽  
Bead Geometry ◽  
Transfer Mode ◽  
Metal Arc Welding ◽  
Preparation Phase ◽  
Metal Transfer Mode ◽  
The Comparative Study ◽  
Wire Arc Additive Manufacturing ◽  
Best Parameters

The symmetrical nature in the case of wall fabrication by wire arc additive manufacturing (WAAM) has been observed in the literature, but it has not been studied as a source of knowledge. This paper focuses on the comparative study of three drop transfer methods employing Gas Metal Arc Welding (GMAW) technology, one of the most reported for the manufacture of aluminum alloys. The transfer modes studied are the well-known pulsed GMAW, cold arc, and the newer pulsed AC. The novelty of the last transfer mode is the reversal of the polarity during the preparation phase of the substance for droplet deposition. This study compares the symmetry of zero beads to determine the best parameters and transfer modes for wire arc additive manufacturing of 5 series aluminum. The pulsed transfer modes show values of 0.6 for symmetry ratio, which makes them more interesting strategies than cold arc with a symmetry ratio of 0.5. Furthermore, the methodology proposed in this study can be extrapolated to other materials manufactured with this technology.

Investigating the Reproducibility of the Wire Arc Additive Manufacturing Process

2021 ◽  
Vol 1161 ◽  
pp. 95-104
Author(s):  
Christoph Halisch ◽  
Christof Gaßmann ◽  
Thomas Seefeld
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Systems ◽  
Aerospace Industry ◽  
Layer By Layer ◽  
Aerospace Application ◽  
Process Qualification ◽  
Welding Head ◽  
Wire Arc Additive Manufacturing ◽  
Tomography Analysis ◽  
Complete Process

Wire arc additive manufacturing (WAAM) of titanium parts shows promising potential for aerospace application due to its high deposition rates allowing a fast and economical production of large integral parts. However, due to the demands of aerospace industry an extensive qualification procedure is necessary to enable the parts as ready to fly. Nowadays, qualification for additive manufactured parts is a time-consuming process, so the advantages in additive manufacturing cannot be fully utilized. For this reason, a complete process qualification for WAAM would reduce the costs drastically in contrast to qualifying manufactured parts individually. As a first step the robustness and reproducibility of the energy reduced WAAM process was investigated. Thick-walled samples are manufactured layer by layer with an oscillating welding head motion. The mechanical properties of the samples are compared on an adequate statistical basis. Microstructural-and computer tomography analysis are conducted to comprehend shown interactions. The reproducibility is investigated in dependence of different heat treatment states, different directions of mechanical testing and two manufacturing systems of the same type.

Bead Modelling and Deposition Path Planning in Wire Arc Additive Manufacturing of Three Dimensional Parts

2019 ◽  
Vol 969 ◽  
pp. 582-588 ◽  
Author(s):  
Ashish Kumar ◽  
Kuntal Maji
Keyword(s):  
Additive Manufacturing ◽  
Three Dimensional ◽  
Bead Geometry ◽  
Post Processing ◽  
Bead Width ◽  
Cross Sectional ◽  
Current Electrode ◽  
Wire Material ◽  
Single Bead ◽  
Wire Arc Additive Manufacturing

This paper presents investigations on the manufacturing of three-dimensional functional metallic parts through melting and deposition of stainless steel 430L wire material by a metal inert gas welding technique. Experiments were performed on wire arc additive manufacturing following face centered composite design of experiments considering voltage, current, electrode wire material feed rate and welding speed as inputs for modeling single bead geometry in terms of bead width, height, and cross-sectional area. Response surface models were built using the collected experimental data. Performance of the models in predicting the responses was found satisfactory. Models of single bead geometry were employed to calculate void and post-processing in fabricating three-dimensional parts following raster scanning deposition of multiple layers considering the different degree of overlapping and build directions. The theoretically estimated values of void and post-processing were verified through fabrications of two three-dimensional shapes. It was shown that the void and post-processing could be controlled by suitable selection of process parameters, the degree of overlapping between two beads and build direction.

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