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  <doc>
    <id>65231</id>
    <completedYear/>
    <publishedYear>2025</publishedYear>
    <thesisYearAccepted/>
    <language>eng</language>
    <pageFirst/>
    <pageLast/>
    <pageNumber/>
    <edition/>
    <issue/>
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    <type>lecture</type>
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    <belongsToBibliography>0</belongsToBibliography>
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    <thesisDateAccepted>--</thesisDateAccepted>
    <title language="eng">Automated in situ monitoring and analysis of process signatures and build profiles during wire arc directed energy deposition</title>
    <abstract language="eng">Wire arc directed energy deposition (DED-Arc) is an emerging metal additive manufacturing process to build near-net shaped metallic parts in a layer-by-layer with minimal material wastage. Automated in situ monitoring and fast-responsive analyses of process signatures and deposit profiles during DED-Arc are in ever demand to print dimensionally consistent parts and reduce post-deposition machining. A comprehensive experimental investigation is presented here involving real-time synchronous measurement of arc current, voltage, and the deposit profile using a novel multi-sensor monitoring framework integrated with the DED-Arc set-up. The recorded current–voltage transients are used to estimate the time-averaged arc power, and energy input in real time for an insight of the influence of wire feed rate and printing travel speed on the deposit characteristics. A unique attempt is made to represent the geometric profiles of the single-track deposits in a generalized mathematical form corresponding to a segmented ellipse, which has exhibited the minimum root-mean-square error of 0.03 mm. The dimensional inconsistency of multi-track deposits is evaluated quantitatively in terms of waviness using build profile monitoring and automated estimation, which is found to increase with an increase in step-over ratio and energy input. For the multi-track mild steel deposits, the suitable range of step-over ratio for the minimum surface waviness is observed to lie between 0.6 and 0.65. Collectively, the proposed framework of synchronized process monitoring and real-time analysis provides a pathway to achieve dimensionally consistent and defect-free parts, and highlights the potential for closed-loop control systems for a wider industrial application of DED-Arc.</abstract>
    <enrichment key="eventName">IIW Annual Assembly 2025</enrichment>
    <enrichment key="eventPlace">Genova, Italy</enrichment>
    <enrichment key="eventStart">23.06.2025</enrichment>
    <enrichment key="eventEnd">25.06.2025</enrichment>
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    <author>Prashant Kumar Chaurasia</author>
    <author>Fabry Cagtay</author>
    <author>Pittner Andreas</author>
    <author>Michael Rethmeier</author>
    <subject>
      <language>eng</language>
      <type>uncontrolled</type>
      <value>Additive Manufacturing</value>
    </subject>
    <subject>
      <language>eng</language>
      <type>uncontrolled</type>
      <value>Arc welding</value>
    </subject>
    <subject>
      <language>eng</language>
      <type>uncontrolled</type>
      <value>Real-time monitoring and control</value>
    </subject>
    <subject>
      <language>eng</language>
      <type>uncontrolled</type>
      <value>Dimensional inconsistency</value>
    </subject>
    <subject>
      <language>eng</language>
      <type>uncontrolled</type>
      <value>DED-arc</value>
    </subject>
    <collection role="ddc" number="620">Ingenieurwissenschaften und zugeordnete Tätigkeiten</collection>
    <collection role="institutes" number="">9 Komponentensicherheit</collection>
    <collection role="institutes" number="">9.3 Schweißtechnische Fertigungsverfahren</collection>
    <collection role="themenfelder" number="">Material</collection>
    <collection role="fulltextaccess" number="">Datei im Netzwerk der BAM verfügbar ("Closed Access")</collection>
    <collection role="literaturgattung" number="">Präsentation</collection>
    <collection role="themenfelder" number="">Additive Fertigung</collection>
  </doc>
  <doc>
    <id>65232</id>
    <completedYear/>
    <publishedYear>2025</publishedYear>
    <thesisYearAccepted/>
    <language>eng</language>
    <pageFirst/>
    <pageLast/>
    <pageNumber/>
    <edition/>
    <issue/>
    <volume/>
    <type>lecture</type>
    <publisherName/>
    <publisherPlace/>
    <creatingCorporation/>
    <contributingCorporation/>
    <belongsToBibliography>0</belongsToBibliography>
    <completedDate>--</completedDate>
    <publishedDate>--</publishedDate>
    <thesisDateAccepted>--</thesisDateAccepted>
    <title language="eng">Automated Arc Welding and Sensor Based Quality Assessment for Enhancing Fatigue Strength and Structural Reliability of Offshore Wind Turbine Supports</title>
    <abstract language="eng">Offshore wind energy plays a crucial role in achieving a carbon dioxide free industrial sector in the coming decades. However, foundation systems for offshore wind turbines significantly impact the overall installation process, posing technical and regulatory challenges. Adopting lightweight design principles in steel construction such as dissolved load bearing structures in jacket foundations offers substantial potential for reducing resource consumption, particularly steel usage. This presentation explores the complete digitalization of welding manufacturing and testing processes, enabling fully automated production and data driven quality assessment of tubular nodes, which are vital components of jacket foundations. The study also investigates the relationship between seam geometry and fatigue strength inspired by bionic design principles. The results demonstrate that tubular nodes can be welded entirely automatically, accommodating geometric tolerances, and that seam geometries ca n be precisely manufactured according to suggestions from e.g. numerical models or other sources . These advancements significantly enhance the fatigue strength and service life of offshore wind turbine support structures.</abstract>
    <enrichment key="eventName">IIW Annual Assembly 2025</enrichment>
    <enrichment key="eventPlace">Genova, Italy</enrichment>
    <enrichment key="eventStart">23.06.2025</enrichment>
    <enrichment key="eventEnd">25.06.2025</enrichment>
    <enrichment key="InvitedTalks">0</enrichment>
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    <author>Andreas Pittner</author>
    <author>Cagtay Fabry</author>
    <author>Marc Thiele</author>
    <author>Antoni Artinov</author>
    <author>Michael Rethmeier</author>
    <subject>
      <language>eng</language>
      <type>uncontrolled</type>
      <value>Automated gas metal arc welding</value>
    </subject>
    <subject>
      <language>eng</language>
      <type>uncontrolled</type>
      <value>Quality assessment and control</value>
    </subject>
    <subject>
      <language>eng</language>
      <type>uncontrolled</type>
      <value>Support structures</value>
    </subject>
    <subject>
      <language>eng</language>
      <type>uncontrolled</type>
      <value>Fatigue</value>
    </subject>
    <collection role="ddc" number="621">Angewandte Physik</collection>
    <collection role="institutes" number="">9 Komponentensicherheit</collection>
    <collection role="institutes" number="">9.3 Schweißtechnische Fertigungsverfahren</collection>
    <collection role="themenfelder" number="">Energie</collection>
    <collection role="fulltextaccess" number="">Datei im Netzwerk der BAM verfügbar ("Closed Access")</collection>
    <collection role="literaturgattung" number="">Präsentation</collection>
    <collection role="themenfelder" number="">Windenergie</collection>
  </doc>
  <doc>
    <id>65681</id>
    <completedYear/>
    <publishedYear>2026</publishedYear>
    <thesisYearAccepted/>
    <language>eng</language>
    <pageFirst>1</pageFirst>
    <pageLast>15</pageLast>
    <pageNumber/>
    <edition/>
    <issue>1</issue>
    <volume>1342</volume>
    <type>article</type>
    <publisherName>IOP Publishing</publisherName>
    <publisherPlace/>
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    <belongsToBibliography>0</belongsToBibliography>
    <completedDate>--</completedDate>
    <publishedDate>--</publishedDate>
    <thesisDateAccepted>--</thesisDateAccepted>
    <title language="eng">Digitalisation and Carbon Footprint Evaluation of Gas Metal Arc Welding and Wire-Arc Directed Energy Deposition</title>
    <abstract language="eng">This paper showcases how a holistic approach to digitalisation enables data-driven welding applications, exemplarily for a gas metal arc welding (GMAW) laboratory. The workflow integrates advanced process monitoring, synchronised multi-sensor data acquisition and tools for data analytics. A welding domain-specific data exchange format weldx is presented that unifies and aggregates the data sets acquired during process monitoring with final component quality metrics, supporting reuse, traceability, and reproducibility. Two case studies illustrate the approach. First, GMAW parameters are adaptively adjusted according to local seam geometry to compensate joint-preparation deviations from nominal values typical for large-scale steel fabrication. Second, the seamless data aggregation along the welding production chain enables an automatic life-cycle assessment (LCA), quantifying the environmental impacts of additive manufacturing with DED Arc/M and attributing the dominant contributors to the carbon footprint. Collectively, the results indicate that a fully integrated experimental set-up together with standardised data structures and scalable analytics can couple monitoring, control, and sustainability, thereby realising the potential of digitalisation for high-quality and environmentally informed welding production.</abstract>
    <parentTitle language="eng">IOP Conference Series: Materials Science and Engineering</parentTitle>
    <identifier type="issn">1757-8981</identifier>
    <identifier type="doi">10.1088/1757-899X/1342/1/012067</identifier>
    <identifier type="urn">urn:nbn:de:kobv:b43-656812</identifier>
    <enrichment key="opus_doi_flag">true</enrichment>
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    <licence>Creative Commons - CC BY - Namensnennung 4.0 International</licence>
    <author>Çağtay Fabry</author>
    <author>Andreas Pittner</author>
    <author>Alexander Kaplan</author>
    <author>Michael Rethmeier</author>
    <subject>
      <language>eng</language>
      <type>uncontrolled</type>
      <value>Digitalisation</value>
    </subject>
    <subject>
      <language>eng</language>
      <type>uncontrolled</type>
      <value>Arc welding</value>
    </subject>
    <subject>
      <language>eng</language>
      <type>uncontrolled</type>
      <value>DED-arc</value>
    </subject>
    <subject>
      <language>eng</language>
      <type>uncontrolled</type>
      <value>Life Cycle Assessment</value>
    </subject>
    <collection role="ddc" number="620">Ingenieurwissenschaften und zugeordnete Tätigkeiten</collection>
    <collection role="institutes" number="">9 Komponentensicherheit</collection>
    <collection role="institutes" number="">9.3 Schweißtechnische Fertigungsverfahren</collection>
    <collection role="themenfelder" number="">Material</collection>
    <collection role="themenfelder" number="">Degradationsmechanismen</collection>
    <collection role="literaturgattung" number="">Verlagsliteratur</collection>
    <collection role="fulltextaccess" number="">Datei für die Öffentlichkeit verfügbar ("Open Access")</collection>
    <collection role="unnumberedseries" number="">Wissenschaftliche Artikel der BAM</collection>
    <thesisPublisher>Bundesanstalt für Materialforschung und -prüfung (BAM)</thesisPublisher>
    <file>https://opus4.kobv.de/opus4-bam/files/65681/Fabry2026a - Digitalisation and Carbon Footprint Evaluation of GMAW and DED-Arc.pdf</file>
  </doc>
</export-example>
