Control Design for Automation of Robotized Laser Metal-wire Deposition

Heralic, Almir; Christiansson, Anna-Karin; Hurtig, Kjell; Ottosson, Mattias; Lennartson, Bengt

doi:10.3182/20080706-5-kr-1001.02503

Cited by 22 publications

(32 citation statements)

References 17 publications

(16 reference statements)

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“…Of these six types, residual stress, structural distortion and thermal dissipation are associated with thermal history (Ding et al 2011;Colegrove et al 2013;Xiong et al 2016). The lack of fusion and porosity are related to process parameters (Heralić 2012;Cong et al 2014). Cracks are normally associated with residual stress (Jhavar et al 2014).…”

Section: Critique Of the Literaturementioning

confidence: 99%

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Realisation of a multi-sensor framework for process monitoring of the wire arc additive manufacturing in producing Ti-6Al-4V parts

Dhokia

Colegrove

et al. 2018

International Journal of Computer Integrated Manufacturing

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Wire arc additive manufacturing (WAAM) is arc welding based additive manufacture which is providing a major opportunity for the aerospace industry to reduce buy-to-fly ratios from 20:1 with forging and machining to 5:1 with WAAM. The WAAM method can build a wide range of near net shapes from a variety of high grade (metallic) materials at high deposition speeds without the need for costly moulds. However, current WAAM methods and technologies are unable to produce parts reliably and with consistent structural material properties and required dimensional accuracy. This is due to the complexity of the process and the lack of process control strategies. This paper makes a brief review on monitoring methods that have been used in WAAM or similar processes. The authors then identify the requirements for a WAAM monitoring system based on the common attributes of the process. Finally, a novel multi-sensor framework is realised which monitors the system voltage/current, part profile and environmental oxygen level. The authors provide a new signal process technique to acquire accurate voltage and current signal without random noises thereby significantly improving the quality of WAAM manufacturing.

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Section: Critique Of the Literaturementioning

confidence: 99%

“…Thermal dissipation is normally monitored by a pyrometer and thermal camera (Almeida and Williams, 2010). The lack of fusion, porosity and cracking are normally accompanied with relatively high energy variation (Heralić, 2012). An acoustic sensor can measure the energy variation during the welding process.…”

Section: Critique Of the Literaturementioning

confidence: 99%

Realisation of a multi-sensor framework for process monitoring of the wire arc additive manufacturing in producing Ti-6Al-4V parts

Dhokia

Colegrove

et al. 2018

International Journal of Computer Integrated Manufacturing

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“…From Equation (9), we know (10) This value should lie within the range of the coefficient of friction between polyurethane and steel.…”

Section: ) Force Analysismentioning

confidence: 99%

“…The use of metallic wires as a deposition material in the field of laser manufacturing is gaining popularity, and the number of feasible industrial applications is still growing [1].Many researchers have been studying basic process characteristics of wire-based additive manufacturing and material properties of deposited beads and 3D parts [2][3][4][5][6][7][8][9][10].…”

mentioning

confidence: 99%

Microwire Feeder for Laser Applications

Shenoy¹,

Liou

2013

BER

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Abstract-This paper focuses on the design and development of a fine microwire feeder for laser applications. The use of metallic wires as a medium of deposition has been popular in aerospace and car manufacturing industries. These micro sized wires are also gaining importance in medical and semi-conductor industries. The use of wire-feeders in laser welding and electrical discharge machining applications has been prominent. There are devices used in laser applications which can handle wires from 0.25mm to 10.0 mm in diameter. The handling of microsized wire in laser application is often considered difficult due to its low buckling strength exposure to harsh environment. The primary function of the microwire feeder described in this paper was to feed wires of varying microdiameters to a desired location with high accuracy and precision to be used in a laser aided manufacturing processes. This can be designed by dividing the microwire feeder into four basic sub-mechanisms: (1) feeding mechanism (2) transfer mechanism (3) precision guidance mechanism (4) adjustment mechanism. These sub-mechanisms are integrated to account for compactness, flexibility and precision. This microwire feeder is capable of handling wires as low as 0.05 mm in diameter. The precision and accuracy of the device was experimentally tested prior to its practical application. A case study on laser deposition was presented; where; a 316 stainless steel microwire of 0.125 mm diameter was fed into a melt pool of 0.2 mm. The wire feed and the traverse speed of the table were varied to achieve a uniformly distributed clad. The effect of wire feed and traverse speed were studied and a deposition process window was developed for future experimentation.

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“…[17][18][19][20][21][22][23][24][25][26][27][28][29][30] Besides, some of them have used special mechanical systems such as four-axis CNC milling machines or three-dimensional (3D)-positioned CNC machines. [31][32][33][34][35][36] In the literature, it was experienced that the integrated systems are really complicated and limited to special codes and machine languages which mean that these systems are considered as closed systems used for generating the deposition paths. Actual robot paths are directly calculated from the computer-aided design (CAD) geometry.…”

Section: Introductionmentioning

confidence: 99%

Development and control of shaped metal deposition process using tungsten inert gas arc heat source in additive layered manufacturing

Ugla

Yilmaz

Almusawi

2016

Proceedings of the Institution of Mechanical Engineers, Part B:

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Tungsten inert gas arc welding-based shaped metal deposition is a novel additive manufacturing technology which can be used for fabricating solid dense parts by melting a cold wire on a substrate in a layer-by-layer manner via continuous DC arc heat. The shaped metal deposition method would be an alternative way to traditional manufacturing methods, especially for complex featured and large-scale solid parts manufacturing, and it is particularly used for aerospace structural components, manufacturing, and repairing of die/molds and middle-sized dense parts. This article presents the designing, constructing, and controlling of an additive manufacturing system using tungsten inert gas plus wire-based shaped metal deposition method. The aim of this work is to design and develop tungsten inert gas plus wire-based shaped metal deposition system to be used for fabricating different components directly from computer-aided design data with minimum time consumed in programming and less boring task compared to conventional robotic systems. So, this article covers the important design steps from computer-aided design data to the final deposited part. The developed additive system is capable of producing near-net-shaped components of sizes not exceeding 400 mm in three-dimensional directly from computer-aided design drawing. The results showed that the developed system succeeded to produce near-netshaped parts for various features of SS308LSi components. Additionally, workshop tests have been conducted in order to verify the capability and reliability of the developed additive manufacturing system. The developed system is also capable of reducing the buy-to-fly ratio from 5 to 2 by reducing waste material from 1717 to 268 g for the sample components.

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Control Design for Automation of Robotized Laser Metal-wire Deposition

Cited by 22 publications

References 17 publications

Realisation of a multi-sensor framework for process monitoring of the wire arc additive manufacturing in producing Ti-6Al-4V parts

Realisation of a multi-sensor framework for process monitoring of the wire arc additive manufacturing in producing Ti-6Al-4V parts

Microwire Feeder for Laser Applications

Development and control of shaped metal deposition process using tungsten inert gas arc heat source in additive layered manufacturing

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