scholarly journals Vision-Based Melt Pool Monitoring for Wire-Arc Additive Manufacturing Using Deep Learning Method

2021 ◽  
Author(s):  
Chunyang Xia ◽  
Zengxi Pan ◽  
Yuxing Li ◽  
Huijun Li
Keyword(s):  
Deep Learning ◽  
Additive Manufacturing ◽  
Large Scale ◽  
Deposition Process ◽  
Utilization Rate ◽  
High Deposition Rate ◽  
Promising Alternative ◽  
Visual Monitoring ◽  
Melt Pool ◽  
Wire Arc Additive Manufacturing

Abstract Wire-arc additive manufacturing (WAAM) technology has been widely recognized as a promising alternative for fabricating large-scale components, due to its advantages of high deposition rate and high material utilization rate. However, some anomalies may occur during the deposition process, such as humping, spattering, and robot suspend. this study proposed to apply Deep Learning in the visual monitoring to diagnose different anomalies during WAAM process. The melt pool images of different anomalies were collected for training and validation by a visual monitoring system. The classification performance of several representative CNN architectures, including ResNet, EfficientNet, VGG-16 and GoogLeNet, were investigated and compared. The classification accuracy of 97.62%, 97.45%, 97.15% and 97.25% was achieved by each model. The results proved that the CNN models are effective in classifying different types of melt pool images of WAAM. Our study is applicable beyond WAAM and should benefit other additive manufacturing or arc welding techniques.

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.

scholarly journals Analysis of the Wall Geometry with Different Strategies for High Deposition Wire Arc Additive Manufacturing of Mild Steel

Metals ◽  
2020 ◽  
Vol 10 (7) ◽  
pp. 892 ◽  
Author(s):  
Eider Aldalur ◽  
Fernando Veiga ◽  
Alfredo Suárez ◽  
Jon Bilbao ◽  
Aitzol Lamikiz
Keyword(s):  
Additive Manufacturing ◽  
Gas Metal Arc Welding ◽  
Low Carbon Steel ◽  
Utilization Rate ◽  
High Deposition Rate ◽  
Low Carbon ◽  
Metal Arc Welding ◽  
Geometric Precision ◽  
Directed Energy ◽  
Wire Arc Additive Manufacturing

Additive manufacturing has gained relevance in recent decades as an alternative to the manufacture of metal parts. Among the additive technologies, those that are classified as Directed Energy Deposition (DED) are characterized by their high deposition rate, noticeably, Wire Arc Additive Manufacturing (WAAM). However, having the inability to produce parts with acceptable final surface quality and high geometric precision is to be considered an important disadvantage in this process. In this paper, different torch trajectory strategies (oscillatory motion and overlap) in the fabrication of low carbon steel walls will be compared using Gas Metal Arc Welding (GMAW)-based WAAM technology. The comparison is done with a study of the mechanical and microstructural characteristics of the produced walls and finally, addressing the productivity obtained utilizing each strategy. The oscillation strategy shows better results, regarding the utilization rate of deposited material and the flatness of the upper surface, this being advantageous for subsequent machining steps.

scholarly journals Finite Element Modeling and Validation of Metal Deposition in Wire Arc Additive Manufacturing

2021 ◽  
pp. 61-66
Author(s):  
Akram Chergui ◽  
Nicolas Beraud ◽  
Frédéric Vignat ◽  
François Villeneuve
Keyword(s):  
Finite Element ◽  
Additive Manufacturing ◽  
Large Scale ◽  
Low Cost ◽  
Source Model ◽  
Metal Deposition ◽  
High Deposition Rate ◽  
Element Technique ◽  
Metallic Parts ◽  
Wire Arc Additive Manufacturing

AbstractWire arc additive manufacturing allows the production of metallic parts by depositing beads of weld metal using arc-welding technologies. This low-cost additive manufacturing technology has the ability to manufacture large-scale parts at a high deposition rate. However, the quality of the obtained parts is greatly affected by the various thermal phenomena present during the manufacturing process. Numerical simulation remains an effective tool for studying such phenomena. In this work, a new finite element technique is proposed in order to model metal deposition in WAAM process. This technique allows to gradually construct the mesh representing the deposited regions along the deposition path. The heat source model proposed by Goldak is adapted and combined with the proposed metal deposition technique taking into account the energy distribution between filler material and the molten pool. The effectiveness of the proposed method is validated by series of experiments, of which an example is detailed in this paper.

scholarly journals A Review of Aluminum Alloy Fabricated by Different Processes of Wire Arc Additive Manufacturing

2021 ◽  
Vol 27 (1) ◽  
pp. 18-26
Author(s):  
Zeli WANG ◽  
Yuanbin ZHANG
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
Additive Manufacturing ◽  
Topological Optimization ◽  
Utilization Rate ◽  
Future Research ◽  
General Tendency ◽  
High Deposition Rate ◽  
Microstructure And Mechanical Properties ◽  
Wire Arc Additive Manufacturing

Due to the advantages of high deposition rate, low equipment cost and high material utilization rate, aluminum alloy fabricated by wire arc additive manufacturing (WAAM) has been widely concerned by scholars and scientific institutions. This article reviews the features of aluminum alloy fabricated by different WAAM processes (GMAW-based, GTAW-based, CMT-based, PAW-based). Research status of the porosity, dimensional accuracy, microstructure and mechanical properties of aluminum alloy in different process is analyzed. General tendency of microstructure and mechanical properties were discussed, and suggestions for the future research direction were put forward including mandatory constraint on molten pool and structural topological optimization.

Wire Arc Additive Manufacturing (WAAM): Reviewing Technology, Mechanical Properties, Applications and Challenges

2020 ◽  
Author(s):  
Moosa Zahid ◽  
Khizar Hai ◽  
Mujtaba Khan ◽  
Ahmed Shekha ◽  
Salman Pervaiz ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Large Scale ◽  
Manufacturing Sector ◽  
Economic Feasibility ◽  
Inert Gas ◽  
High Deposition Rate ◽  
Design Concepts ◽  
Industrial Sectors ◽  
Wire Arc Additive Manufacturing

Abstract Because of the flexible nature of 3D printing and additive manufacturing technology, manufacturing sector has been revolutionized. There is a possibility to manufacture different intricate geometrics that cannot be produced through conventional processes previously. The conventional design concepts such as design for manufacture (DFM) and design for assembly (DFA) have been modified and simplified. Wire arc additive manufacturing (WAAM) has emerged as one of the leading additive manufacturing (AM) processes due to its high deposition rate and economic feasibility. A lot of progress has been made to understand and improve this process and the mechanical properties associated with the fabricated parts. It is specifically cheaper to print large-scale metallic components using WAAM. This paper gives a thorough review of the work that has been done on WAAM by comparing different technological variants of WAAM, which include Metal Inert Gas (MIG), Tungsten Inert Gas (TIG) and Plasma Arc Welding (PAW). The study also discusses the mechanical properties of the fabricated components using different metals, the defects and challenges the process faces today and how they can be reduced. In the end the study also provides overview of WAAM applications in some of the industrial sectors such as construction, automotive, and structural etc.

scholarly journals High-Temperature Mechanical Properties of IN718 Alloy: Comparison of Additive Manufactured and Wrought Samples

Crystals ◽  
2020 ◽  
Vol 10 (8) ◽  
pp. 689
Author(s):  
Trunal Bhujangrao ◽  
Fernando Veiga ◽  
Alfredo Suárez ◽  
Edurne Iriondo ◽  
Franck Girot Mata
Keyword(s):  
Mechanical Properties ◽  
High Temperature ◽  
Additive Manufacturing ◽  
Large Scale ◽  
Low Cost ◽  
Tensile Tests ◽  
High Deposition Rate ◽  
High Temperature Mechanical Properties ◽  
Manufacturing Techniques ◽  
Wire Arc Additive Manufacturing

Wire Arc Additive Manufacturing (WAAM) is one of the most appropriate additive manufacturing techniques for producing large-scale metal components with a high deposition rate and low cost. Recently, the manufacture of nickel-based alloy (IN718) using WAAM technology has received increased attention due to its wide application in industry. However, insufficient information is available on the mechanical properties of WAAM IN718 alloy, for example in high-temperature testing. In this paper, the mechanical properties of IN718 specimens manufactured by the WAAM technique have been investigated by tensile tests and hardness measurements. The specific comparison is also made with the wrought IN718 alloy, while the microstructure was assessed by scanning electron microscopy and X-ray diffraction analysis. Fractographic studies were carried out on the specimens to understand the fracture behavior. It was shown that the yield strength and hardness of WAAM IN718 alloy is higher than that of the wrought alloy IN718, while the ultimate tensile strength of the WAAM alloys is difficult to assess at lower temperatures. The microstructure analysis shows the presence of precipitates (laves phase) in WAAM IN718 alloy. Finally, the effect of precipitation on the mechanical properties of the WAAM IN718 alloy was discussed in detail.

scholarly journals Compression Behaviour of Wire + Arc Additive Manufactured Structures

Metals ◽  
2021 ◽  
Vol 11 (6) ◽  
pp. 877
Author(s):  
Masoud Abbaszadeh ◽  
Volker Ventzke ◽  
Leonor Neto ◽  
Stefan Riekehr ◽  
Filomeno Martina ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Large Scale ◽  
Grain Morphology ◽  
Electron Back Scatter Diffraction ◽  
Compression Tests ◽  
Homogeneous Microstructure ◽  
Compression Loading ◽  
Anisotropic Behaviour ◽  
Mechanical And Microstructural Properties ◽  
Wire Arc Additive Manufacturing

Increasing demand for producing large-scale metal components via additive manufacturing requires relatively high building rate processes, such as wire + arc additive manufacturing (WAAM). For the industrial implementation of this technology, a throughout understanding of material behaviour is needed. In the present work, structures of Ti-6Al-4V, AA2319 and S355JR steel fabricated by means of WAAM were investigated and compared with respect to their mechanical and microstructural properties, in particular under compression loading. The microstructure of WAAM specimens is assessed by scanning electron microscopy, electron back-scatter diffraction, and optical microscopy. In Ti-6Al-4V, the results show that the presence of the basal and prismatic crystal planes in normal direction lead to an anisotropic behaviour under compression. Although AA2319 shows initially an isotropic plastic behaviour, the directional porosity distribution leads to an anisotropic behaviour at final stages of the compression tests before failure. In S355JR steel, isotropic mechanical behaviour is observed due to the presence of a relatively homogeneous microstructure. Microhardness is related to grain morphology variations, where higher hardness near the inter-layer grain boundaries for Ti-6Al-4V and AA2319 as well as within the refined regions in S355JR steel is observed. In summary, this study analyzes and compares the behaviour of three different materials fabricated by WAAM under compression loading, an important loading condition in mechanical post-processing techniques of WAAM structures, such as rolling. In this regard, the data can also be utilized for future modelling activities in this direction.

Accelerating Large-Format Metal Additive Manufacturing: How Controls R&D Is Driving Speed, Scale, and Efficiency

2020 ◽  
Author(s):  
Brian T. Gibson ◽  
Paritosh Mhatre ◽  
Michael C. Borish ◽  
Justin L. West ◽  
Emma D. Betters ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Large Scale ◽  
Closed Loop ◽  
Size Control ◽  
Pool Size ◽  
Large Format ◽  
Layer Height ◽  
Melt Pool ◽  
The Impact ◽  
Melt Pool Size

Abstract This article highlights work at Oak Ridge National Laboratory’s Manufacturing Demonstration Facility to develop closed-loop, feedback control for laser-wire based Directed Energy Deposition, a form of metal Big Area Additive Manufacturing (m-BAAM), a process being developed in partnership with GKN Aerospace specifically for the production of Ti-6Al-4V pre-forms for aerospace components. A large-scale structural demonstrator component is presented as a case-study in which not just control, but the entire 3D printing workflow for m-BAAM is discussed in detail, including design principles for large-format metal AM, toolpath generation, parameter development, process control, and system operation, as well as post-print net-shape geometric analysis and finish machining. In terms of control, a multi-sensor approach has been utilized to measure both layer height and melt pool size, and multiple modes of closed-loop control have been developed to manipulate process parameters (laser power, print speed, deposition rate) to control these variables. Layer height control and melt pool size control have yielded excellent local (intralayer) and global (component-level) geometry control, and the impact of melt pool size control in particular on thermal gradients and material properties is the subject of continuing research. Further, these modes of control have allowed the process to advance to higher deposition rates (exceeding 7.5 lb/hr), larger parts (1-meter scale), shorter build times, and higher overall efficiency. The control modes are examined individually, highlighting their development, demonstration, and lessons learned, and it is shown how they operate concurrently to enable the printing of a large-scale, near net shape Ti-6Al-4V component.

A Literature Review on the Wire and Arc Additive Manufacturing—Welding Systems and Software

2021 ◽  
Vol 13 (8) ◽  
pp. 1391-1400
Author(s):  
Zidong Lin ◽  
Pengfei Liu ◽  
Xinghua Yu
Keyword(s):  
Additive Manufacturing ◽  
Large Scale ◽  
Tool Path ◽  
Future Research ◽  
High Deposition Rate ◽  
Efficient Technology ◽  
The Past ◽  
Material Efficiency ◽  
Systems Software ◽  
Design Generation

Wire and arc additive manufacturing (WAAM) is considered to be an economic and efficient technology that is suitable to produce large-scale and ultra-large-scale metallic components. In the past two decades, it has been widely investigated in different fields, such as aerospace, automotive and marine industries. Due to its relatively high deposition rate, material efficiency, and shortened lead time compared to other powder-based additive manufacturing (AM) techniques, wire and arc additive manufacturing (WAAM) has been significantly noticed and adopted by both academic researchers and industrial engineers. In order to summarize the development achievements of wire and arc additive manufacturing (WAAM) in the past few years and outlook the development direction in the coming days, this paper provides an overview of 3D metallic printing by applying it as a deposition method. The review mainly focuses on the current welding systems, software for tool path design, generation, and planning used in wire and arc additive manufacturing (WAAM). In the end, the state of the art and future research on wire and arc additive manufacturing (WAAM) have been prospected.

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