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In Laser Wire Additive Manufacturing (LWAM), the final geometry is produced using the layer-by-layer deposition (beads principle). To achieve good geometrical accuracy in the final product, proper implementation of the bead geometry is essential. For this reason, the paper focuses on this process and proposes a layer geometry (width and height) prediction model to improve deposition accuracy. More specifically, a machine learning regression algorithm is applied on several experimental data to predict the bead geometry across layers. Furthermore, a neural network-based approach was used to study the influence of different deposition parameters, namely laser power, wire-feed rate and travel speed on bead geometry. To validate the effectiveness of the proposed approach, a test split validation strategy was applied to train and validate the machine learning models. The results show a particular evolutionary trend and confirm that the process parameters have a direct influence on the bead geometry, and so, too, on the final part. Several deposition parameters have been found to obtain an accurate prediction model with low errors and good layer deposition. Finally, this study indicates that the machine learning approach can efficiently be used to predict the bead geometry and could help later in designing a proper controller in the LWAM process.

Laser Wire Additive Manufacturing (LWAM) is a flexible and fast manufacturing method used to produce variants of high metal geometric complexity. In this work, a physics-based model of the bead geometry including process parameters and material properties was developed for the LWAM process of large-scale products. The developed model aimed to include critical process parameters, material properties and thermal history to describe the relationship between the layer height with different process inputs (i.e., the power, the standoff distance, the temperature, the wire-feed rate, and the travel speed). Then, a Model Predictive Controller (MPC) was designed to keep the layer height trajectory constant taking into consideration the constraints faced in the LWAM technology. Experimental validation results were performed to check the accuracy of the proposed model and the results revealed that the developed model matches the experimental data. Finally, the designed MPC controller was able to track a predefined layer height reference signal by controlling the temperature input of the system.

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In additive manufacturing of Ni-based alloy IN718, what causes Icosahedral Short-Range Order (ISRO) or iQC mediated nucleation of equiaxed grains is still not understood. In order to have a better comprehension of the microstructure formation, a more comprehensive characterization both on grain structure and chemical heterogeneities must be achieved. In this work, a scanning electron microscope equipped with a focused ion beam (FIB) allowed to perform a 3D EDS chemical analysis and EBSD orientation mapping of the volume in an equiaxed grain zone. After the 3D reconstruction of the equiaxed grains has been performed, grain-to-grain orientation analysis allowed to analyze multiple twin boundaries orientation relationships in a volume containing hundreds of grains. Chemical mapping using EDS allowed to identify TiC inclusions from which a five-fold symmetry axis seem to emerge, indicating a potential nucleation site. Such areas were analyzed in transmission electron microscopy (TEM) to investigate the different present phases. The nucleation sequence and potential origin of mediated nucleation are further discussed, opening new prospects for grain refinement in additively manufactured nickel-based alloys.

In recent years, the evolution of computer-aided design technology has established a new design method to improve digital model creations. The new design method is called Parametric Modeling. In this paper, 3D metallic models are printed using a novel Parametric Modeling approach. The goal of this approach is to use parametric design features to simulate and print 3D metallic objects using Laser Wire Additive Manufacturing (LWAM) process. The proposed approach includes a pattern creation and robot targets assignment while considering several process requirements of LWAM and the robot system. This technique will allow the development of an adaptive robot toolpath for a good deposition process. Finally, a wall, a cylinder, and a complex shape were simulated and deposited to validate the proposed approach. The results show that the approach is feasible, adaptive, and can enhance 3D metallic print in the LWAM process.

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