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In wire-arc additive manufacturing, a wire is molten by an electrical or laser arc and deposited droplet-by-droplet to construct the desired workpiece, given as a set of two-dimensional layers. The weld source can move freely over a substrate plate, processing each layer, but there is also the possibility of moving without welding. A primary reason for stress inside the material is the large thermal gradient caused by the weld source, resulting in lower product quality. Thus, it is desirable to control the temperature of the workpiece during the process. One way of its optimization is the trajectory of the weld source. We consider the problem of finding a trajectory of the moving weld source for a single layer of an arbitrary workpiece that maximizes the quality of the part and derive a novel mixed-integer PDE-constrained model, including the calculation of a detailed temperature distribution measuring the overall quality. The resulting optimization problem is linearized and solved using the state-of-the-art numerical solver IBM CPLEX. Its performance is examined by several computational studies.
Since the beginning of its development in the 1950s, mixed integer programming (MIP) has been used for a variety of practical application problems, such as sequence optimization. Exact solution techniques for MIPs, most prominently branch-and-cut techniques, have the advantage (compared to heuristics such as genetic algorithms) that they can generate solutions with optimality certificates. The novel process of additive manufacturing opens up a further perspective for their use. With the two common techniques, Wire Arc Additive Manufacturing (WAAM) and Laser Powder Bed Fusion (LPBD), the sequence in which a given component geometry must be manufactured can be planned. In particular, the heat transfer within the component must be taken into account here, since excessive temperature gradients can lead to internal stresses and warpage after cooling. In order to integrate the temperature, heat transfer models (heat conduction, heat radiation) are integrated into a sequencing model. This leads to the problem class of MIPDECO: MIPs with partial differential equations (PDEs) as further constraints. We present these model approaches for both manufacturing techniques and carry out test calculations for sample geometries in order to demonstrate the feasibility of the approach.