Zitieren Sie bitte immer diesen URN: urn:nbn:de:kobv:b43-642029
Automated in situ monitoring and analysis of process signatures and build profiles during wire arc directed energy deposition
- 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 formWire 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.…


| Autor*innen: | Prashant Kumar ChaurasiaORCiD, Çağtay FabryORCiD, Andreas PittnerORCiD, Amitava DeORCiD, Michael RethmeierORCiD |
|---|---|
| Dokumenttyp: | Zeitschriftenartikel |
| Veröffentlichungsform: | Verlagsliteratur |
| Sprache: | Englisch |
| Titel des übergeordneten Werkes (Englisch): | Progress in Additive Manufacturing |
| Jahr der Erstveröffentlichung: | 2025 |
| Organisationseinheit der BAM: | 9 Komponentensicherheit |
| 9 Komponentensicherheit / 9.3 Schweißtechnische Fertigungsverfahren | |
| Veröffentlichende Institution: | Bundesanstalt für Materialforschung und -prüfung (BAM) |
| Verlag: | Springer Science and Business Media LLC |
| Verlagsort: | Cham |
| Erste Seite: | 1 |
| Letzte Seite: | 20 |
| DDC-Klassifikation: | Technik, Medizin, angewandte Wissenschaften / Ingenieurwissenschaften / Ingenieurwissenschaften und zugeordnete Tätigkeiten |
| Freie Schlagwörter: | Additive Manufacturing; Arc welding; DED-arc; Dimensional inconsistency; Real-time monitoring and control |
| Themenfelder/Aktivitätsfelder der BAM: | Material |
| Material / Additive Fertigung | |
| DOI: | 10.1007/s40964-025-01333-9 |
| URN: | urn:nbn:de:kobv:b43-642029 |
| ISSN: | 2363-9512 |
| Verfügbarkeit des Dokuments: | Datei für die Öffentlichkeit verfügbar ("Open Access") |
| Lizenz (Deutsch): | Creative Commons - CC BY - Namensnennung 4.0 International |
| Datum der Freischaltung: | 26.09.2025 |
| Referierte Publikation: | Ja |
| Datum der Eintragung als referierte Publikation: | 26.09.2025 |
| Schriftenreihen ohne Nummerierung: | Wissenschaftliche Artikel der BAM |


