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

Construction Robotics, vol. 7, pp. 309–328

Abstract

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.

Authors 6

1. Ethan Kerber corresponding Aachen Chair for Individualized Production (IP) Welding and Joining Institute

   RWTH Aachen University

   Affiliation as printed

   RWTH, Chair for Individualized Production (IP), Campus-Boulevard 30, Aachen, 52074, NRW, Germany

   RWTH, Welding and Joining Institute (ISF), Pontstraße 49, Aachen, 52062, NRW, Germany

2. Jan Luca Fahrendholz Aachen Chair for Individualized Production (IP) Welding and Joining Institute

   RWTH Aachen University

   Affiliation as printed

   RWTH, Chair for Individualized Production (IP), Campus-Boulevard 30, Aachen, 52074, NRW, Germany

   RWTH, Welding and Joining Institute (ISF), Pontstraße 49, Aachen, 52062, NRW, Germany

3. Sigrid Brell‐Çokcan Aachen Chair for Individualized Production (IP) Welding and Joining Institute

   RWTH Aachen University

   Affiliation as printed

   RWTH, Chair for Individualized Production (IP), Campus-Boulevard 30, Aachen, 52074, NRW, Germany

   RWTH, Welding and Joining Institute (ISF), Pontstraße 49, Aachen, 52062, NRW, Germany

4. Peter Dewald Aachen Chair for Individualized Production (IP) Welding and Joining Institute

   RWTH Aachen University

   Affiliation as printed

   RWTH, Chair for Individualized Production (IP), Campus-Boulevard 30, Aachen, 52074, NRW, Germany

   RWTH, Welding and Joining Institute (ISF), Pontstraße 49, Aachen, 52062, NRW, Germany

5. Rahul Sharma Aachen Chair for Individualized Production (IP) Welding and Joining Institute

   RWTH Aachen University

   Affiliation as printed

   RWTH, Chair for Individualized Production (IP), Campus-Boulevard 30, Aachen, 52074, NRW, Germany

   RWTH, Welding and Joining Institute (ISF), Pontstraße 49, Aachen, 52062, NRW, Germany

6. Uwe Reisgen Aachen Chair for Individualized Production (IP) Welding and Joining Institute

   RWTH Aachen University

   Affiliation as printed

   RWTH, Chair for Individualized Production (IP), Campus-Boulevard 30, Aachen, 52074, NRW, Germany

   RWTH, Welding and Joining Institute (ISF), Pontstraße 49, Aachen, 52062, NRW, Germany