A wire deflection detection method based on image processing in wire + arc additive manufacturing

Zhan, Qiang; Liang, Yihui; Ding, Jialuo; Williams, Stewart

doi:10.1007/s00170-016-9106-2

Cited by 41 publications

(8 citation statements)

References 21 publications

(15 reference statements)

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“…The consequences are unstable arc behavior, increased spattering or weld seam irregularities such as lack of fusion [29,30]. In WAAM the electrode offset affects the software supported path planning with the risk of dimensional deviations from the CAD model and the work piece [28].…”

Section: Introduction and State Of The Artmentioning

confidence: 99%

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Reduction of Energy Input in Wire Arc Additive Manufacturing (WAAM) with Gas Metal Arc Welding (GMAW)

et al. 2020

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Wire arc additive manufacturing (WAAM) by gas metal arc welding (GMAW) is a suitable option for the production of large volume metal parts. The main challenge is the high and periodic heat input of the arc on the generated layers, which directly affects geometrical features of the layers such as height and width as well as metallurgical properties such as grain size, solidification or material hardness. Therefore, processing with reduced energy input is necessary. This can be implemented with short arc welding regimes and respectively energy reduced welding processes. A highly efficient strategy for further energy reduction is the adjustment of contact tube to work piece distance (CTWD) during the welding process. Based on the current controlled GMAW process an increase of CTWD leads to a reduction of the welding current due to increased resistivity in the extended electrode and constant voltage of the power source. This study shows the results of systematically adjusted CTWD during WAAM of low-alloyed steel. Thereby, an energy reduction of up to 40% could be implemented leading to an adaptation of geometrical and microstructural features of additively manufactured work pieces.

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Section: Introduction and State Of The Artmentioning

confidence: 99%

“…(a) Definition of contact tube to work piece distance (CTWD) and (b) effect of the electrode spin on wire positioning in gas metal arc welding[26][27][28].…”

mentioning

confidence: 99%

Reduction of Energy Input in Wire Arc Additive Manufacturing (WAAM) with Gas Metal Arc Welding (GMAW)

et al. 2020

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“…Chabot, Rauch [7] utilized a thermal camera to monitor the thermal distribution and history during the WAAM process. Zhan, Liang [8] applied a welding camera to monitor wire de ection during the WAAM process. Zhao, Guo [9] collect the spectrum signal and welding pool image to monitor the anomaly during WAAM.…”

Section: Introductionmentioning

confidence: 99%

Vision-based melt pool monitoring for wire-arc additive manufacturing using deep learning method

Xia

Pan

et al. 2022

Int J Adv Manuf Technol

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Wire-arc additive manufacturing (WAAM) technology has been widely recognized as a promising alternative for fabricating large-scale components, due to its advantages of high deposition rate and high material utilization rate. However, some anomalies may occur during the deposition process, such as humping, spattering, and robot suspend. this study proposed to apply Deep Learning in the visual monitoring to diagnose different anomalies during WAAM process. The melt pool images of different anomalies were collected for training and validation by a visual monitoring system. The classi cation performance of several representative CNN architectures, including ResNet, E cientNet, VGG-16 and GoogLeNet, were investigated and compared. The classi cation accuracy of 97.62%, 97.45%, 97.15% and 97.25% was achieved by each model. The results proved that the CNN models are effective in classifying different types of melt pool images of WAAM. Our study is applicable beyond WAAM and should bene t other additive manufacturing or arc welding techniques.

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“…Wire arc additive manufacturing (WAAM) has exhibited unique advantages in large-scale component manufacturing due to its high material utilization rate, high deposition rate, low production and equipment cost, and high equipment flexibility and scalability [1][2][3]. WAAM of aluminum alloys have been widely investigated by researchers.…”

Section: Introductionmentioning

confidence: 99%

The Microstructure and Properties of an Al-Mg-0.3Sc Alloy Deposited by Wire Arc Additive Manufacturing

Ren

Wang³

et al. 2020

Metals

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Al-Mg alloys can reach medium strength without a solid solution and quenching treatment, thereby avoiding product distortion caused by quenching, which has attracted the attention of wire arc additive manufacturing (WAAM) researchers. However, the mechanical properties of the WAAM Al-Mg alloy deposits obtained so far are poor. Herein, we describe the preparation of Al-Mg-0.3Sc alloy deposits by WAAM and detail the pores, microstructure, and mechanical properties of the alloy produced in this manner. The results showed that the number and sizes of the pores in WAAM Al-Mg-0.3Sc alloy deposits were equivalent to those in Al-Mg alloy deposits without Sc. The rapid cooling characteristics of the WAAM process make the precipitation morphology, size, and distribution of the primary and secondary Al3Sc phases unique and effectively improve the mechanical properties of the deposit. A primary Al3Sc phase less than 3 μm in size was found to precipitate from the WAAM Al-Mg-0.3Sc alloy deposits. The primary Al3Sc phase refines grains, changes the segregated β(Mg2Al3) phase morphology, and ensures that the mechanical properties of horizontal and vertical samples of the deposits are uniform. After heat treatment at 350 °C for 1 h, the WAAM Al-Mg-0.3Sc alloy deposits precipitated a secondary Al3Sc phase, which was spherical (diameter about 20 nm) and had high dispersity. This phase blocks dislocations and subgrain boundaries, causes a noticeable strengthening effect, and further improves the mechanical properties of the deposits, up to a horizontal samples tensile strength of 415 MPa, a yield strength of 279 MPa, and an elongation of 18.5%, a vertical samples tensile strength of 411 MPa, a yield strength of 279 MPa, and an elongation of 14.5%. This Al-Mg-Sc alloy is expected to be widely used in the WAAM field.

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A wire deflection detection method based on image processing in wire + arc additive manufacturing

Cited by 41 publications

References 21 publications

Reduction of Energy Input in Wire Arc Additive Manufacturing (WAAM) with Gas Metal Arc Welding (GMAW)

Reduction of Energy Input in Wire Arc Additive Manufacturing (WAAM) with Gas Metal Arc Welding (GMAW)

Vision-based melt pool monitoring for wire-arc additive manufacturing using deep learning method

The Microstructure and Properties of an Al-Mg-0.3Sc Alloy Deposited by Wire Arc Additive Manufacturing

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