Robot Based Wire Arc Additive Manufacturing System with Context-Sensitive Multivariate Monitoring Framework

Abstract Large scale, metal parts are commonly manufactured by milling with a buy-to-fly-ratio of up to 10. A resource efficient alternative is the production by Direct Energy Deposition (DED) based Wire Arc Additive Manufacturing (WAAM). In this study, a WAAM system is divided into four elements (welding source, kinematic structure, control system, monitoring system) and a review is accomplished for each. Requirements are defined based on these reviews and additional needs and a robot based WAAM setup is proposed. To validate the WAAM setup, first experiments are conducted regarding the influence of the orientation of the welding torch respectively of the lead and the tilt angle on the geometry of a deposited wall. Finally, a framework for a seamlessly integrated monitoring system in hybrid manufacturing for enhanced data analysis is introduced. The framework is based on a digital twin of the workpiece in production which serves as base for proactive, context sensitive process adaptions.

[1]  E. Rajasekar,et al.  Cold metal transfer (CMT) technology - An overview , 2017 .

[2]  Gang Wang,et al.  Thermal analysis for single-pass multi-layer GMAW based additive manufacturing using infrared thermography , 2017 .

[3]  Bintao Wu,et al.  Thermal Behavior in Wire Arc Additive Manufacturing: Characteristics, Effects and Control , 2019, Transactions on Intelligent Welding Manufacturing.

[4]  Shanben Chen,et al.  A study of multisensor information fusion in welding process by using fuzzy integral method , 2014 .

[5]  Fang Li,et al.  Adaptive process control of wire and arc additive manufacturing for fabricating complex-shaped components , 2018 .

[6]  Lei Wang,et al.  Correlations between Microstructure Characteristics and Mechanical Properties in 5183 Aluminium Alloy Fabricated by Wire-Arc Additive Manufacturing with Different Arc Modes , 2018, Materials.

[7]  Jun Xiong,et al.  Online measurement of bead geometry in GMAW-based additive manufacturing using passive vision , 2013 .

[8]  M. Murua,et al.  Design and integration of WAAM technology and in situ monitoring system in a gantry machine , 2017 .

[9]  Vimal Dhokia,et al.  Invited review article: Strategies and processes for high quality wire arc additive manufacturing , 2018, Additive Manufacturing.

[10]  Zazuli Mohid,et al.  Effect of GMAW-CMT Heat Input on Weld Bead Profile Geometry for Freeform Fabrication of Aluminium Parts , 2013 .

[11]  Yifan Zhao,et al.  A Passive Imaging System for Geometry Measurement for the Plasma Arc Welding Process , 2017, IEEE Transactions on Industrial Electronics.

[12]  Zhifen Zhang,et al.  Online welding quality monitoring based on feature extraction of arc voltage signal , 2014 .

[13]  J. González,et al.  Additive manufacturing with GMAW welding and CMT technology , 2017 .

[14]  Jurij Prezelj,et al.  USE OF AUDIBLE SOUND FOR ON-LINE MONITORING OF GAS METAL ARC WELDING PROCESS , 2008 .

[15]  C. Doumanidis,et al.  Geometry Regulation of Material Deposition in Near-Net Shape Manufacturing by Thermally Scanned Welding , 2002 .

[16]  Lin Wu,et al.  Bead geometry prediction for robotic GMAW-based rapid manufacturing through a neural network and a second-order regression analysis , 2012, Journal of Intelligent Manufacturing.

[17]  Vimal Dhokia,et al.  Realisation of a multi-sensor framework for process monitoring of the wire arc additive manufacturing in producing Ti-6Al-4V parts , 2018, Int. J. Comput. Integr. Manuf..

[18]  Michael P Sealy,et al.  Hybrid Processes in Additive Manufacturing , 2018 .

[19]  Antonino Squillace,et al.  Selection of Optimal Process Parameters for Wire Arc Additive Manufacturing , 2017 .

[20]  Varun Sharma,et al.  Thin-walled metal deposition with GTAW welding-based additive manufacturing process , 2019, Journal of the Brazilian Society of Mechanical Sciences and Engineering.

[21]  K. P. Karunakaran,et al.  Retrofitment of a CNC machine for hybrid layered manufacturing , 2009 .

[22]  Jurij Prezelj,et al.  Monitoring Gas Metal Arc Welding Process by Using Audible Sound Signal , 2011 .

[23]  O. Company,et al.  Skeleton arc additive manufacturing with closed loop control , 2019, Additive Manufacturing.

[24]  Lin Li,et al.  A novel 6-axis hybrid additive-subtractive manufacturing process: Design and case studies , 2018, Journal of Manufacturing Processes.

[25]  Guilan Wang,et al.  In situ 3D monitoring and control of geometric signatures in wire and arc additive manufacturing , 2019, Surface Topography: Metrology and Properties.

[26]  A. Addison,et al.  Wire + Arc Additive Manufacturing , 2016 .

[27]  Valdemar R. Duarte,et al.  Current Status and Perspectives on Wire and Arc Additive Manufacturing (WAAM) , 2019, Materials.

[28]  YuMing Zhang,et al.  Observation of a dynamic specular weld pool surface , 2006 .

[29]  Manuel Esperon-Miguez,et al.  A qualification procedure to manufacture and repair aerospace parts with electron beam melting , 2016 .

[30]  Bintao Wu,et al.  A review of the wire arc additive manufacturing of metals: properties, defects and quality improvement , 2018, Journal of Manufacturing Processes.

[31]  Gianni Campatelli,et al.  Optimization of WAAM Deposition Patterns for T-crossing Features , 2016 .

[32]  Alain Bernard,et al.  Hybrid rapid manufacturing of metallic objects , 2010 .

[33]  Tin-Chih Toly Chen,et al.  Quality control issues in 3D-printing manufacturing: a review , 2018 .

[34]  Huabin Chen,et al.  A novel control algorithm for weld pool control , 2010, Ind. Robot.

[35]  Lianfa Bai,et al.  Quality monitoring in wire-arc additive manufacturing based on cooperative awareness of spectrum and vision , 2019, Optik.