TY - JOUR A1 - Franke, Jan A1 - Heinrich, Florian A1 - Reisch, Raven T. T1 - Vision based process monitoring in wire arc additive manufacturing (WAAM) JF - Journal of Intelligent Manufacturing (ISSN: 1572-8145) N2 - A stable welding process is crucial to obtain high quality parts in wire arc additive manufacturing. The complexity of the process makes it inherently unstable, which can cause various defects, resulting in poor geometric accuracy and material properties. This demands for in-process monitoring and control mechanisms to industrialize the technology. In this work, process monitoring algorithms based on welding camera image analysis are presented. A neural network for semantic segmentation of the welding wire is used to monitor the working distance as well as the horizontal position of the wire during welding and classic image processing techniques are applied to capture spatter formation. Using these algorithms, the process stability is evaluated in real time and the analysis results enable the direction independent closed-loop-control of the manufacturing process. This significantly improves geometric fidelity as well as mechanical properties of the fabricated part and allows the automated production of parts with complex deposition paths including weld bead crossings, curvatures and overhang structures. KW - Wire arc additive manufacturing KW - Vision based monitoring KW - Machine learning KW - Nozzle-to-work distance monitoring KW - Contact tube wear off detection KW - Spatter detection Y1 - 2024 U6 - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:101:1-2405052141549.085870766506 SN - 0956-5515 SN - 1572-8145 VL - 36 IS - 3 SP - 1711 EP - 1721 PB - Springer US CY - New York ER -