TY - GEN A1 - Israr, Rameez A1 - Buhl, Johannes A1 - Bambach, Markus T1 - A study on power-controlled wire-arc additive manufacturing using a data-driven surrogate model T2 - The International Journal of Advanced Manufacturing Technology N2 - Wire-arc additive manufacturing (WAAM) provides an alternative for the production of various metal products needed in medium to large batch sizes due to its high deposition rates. However, the cyclic heat input in WAAM may cause local overheating. To avoid adverse effects on the performance of the part, interlayer dwelling and active cooling are used, but these measures increase the process time. Alternatively, the temperature during the WAAM process could be controlled by optimizing the welding power. The present work aims at introducing and implementing a novel temperature management approach by adjusting the weld-bead cross-section along with the welding power to reduce the heat accumulation in the WAAM process. The temperature evolution during welding of weld beads of different cross-sections is investigated and a database of the relation between optimal welding power for beads of various sizes and different pre-heating temperatures was established. The numerical results are validated experimentally with a block-shaped geometry. The results show that by the proposed method, the test shape made was welded with lower energy consumption and process time as compared to conventional constant-power WAAM. The proposed approach efficiently manages the thermal input and reduces the need for pausing the process. Hence, the defects related to heat accumulation might be reduced, and the process efficiency increased. Y1 - 2021 UR - https://opus4.kobv.de/opus4-UBICO/frontdoor/index/index/docId/28112 SN - 1433-3015 SN - 0268-3768 VL - 177 IS - 7-8 SP - 2133 EP - 2147 ER -