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A study on power-controlled wire-arc additive manufacturing using a data-driven surrogate model

  • 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.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.show moreshow less

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Metadaten
Author: Rameez Israr, Johannes BuhlORCiD, Markus BambachGND
DOI:https://doi.org/10.1007/s00170-021-07358-y
ISSN:1433-3015
ISSN:0268-3768
Title of the source (English):The International Journal of Advanced Manufacturing Technology
Document Type:Scientific journal article peer-reviewed
Language:English
Year of publication:2021
Volume/Year:177
Issue number:7-8
First Page:2133
Last Page:2147
Faculty/Chair:Fakultät 3 Maschinenbau, Elektro- und Energiesysteme / FG Hybride Fertigung
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