Dynamic WAAM: adaptive processes for equivalent contact surface (ECS) optimization

Abstract

Wire arc additive manufacturing (WAAM) integrates benefits of automation and mass customization to improve efficiency through near-net part production. While WAAM is well researched, there remain significant challenges as the complex relationship between robot, welder, and process parameters can lead to inaccuracy in geometry and variations in material properties. This research proposes a novel framework for quantifying the WAAM process and proposes dynamic adaptive strategies for improving production. This paper introduces the concept of an equivalent contact surface (ECS) for quantifying the additive welding process. Adaptive methods are then identified to optimize WAAM production. In conclusion, this paper provides an outlook on future research directions for continuing the development of this dynamic WAAM process.

Variable Layer Heights in Wire Arc Additive Manufacturing and WAAM Information Models

“…The prc.IoT framework was briefly described in previous research by the authors [16], with the following research going into further detail on its application in WAAM. Prc.IoT leverages the MxAutomation libraries to establish a connection between the command source (MCU) and the robot, with data sent at four-millisecond intervals.…”

“…The WIM data flow is depicted in Figure 14, which illustrates the process of collating data from various sources to create granular information on the process. Further clarification regarding the data structure for distributed communication in Dynamic WAAM can be found in the article by the authors [16]. The collection of data in an organized and scalable format can be accomplished through the Structured Query Language (SQL).…”