Traceability-informed adaptation in wire arc additive manufacturing

The International Journal of Advanced Manufacturing Technology, vol. 144, pp. 5201–5215

Abstract

There is currently no standard framework for traceability to collect data documenting the variables which influence the quality of Wire Arc Additive Manufacturing (WAAM). This work presents a WAAM Information Model (WIM) to enable traceability-informed adaptation. The framework is validated through the printing of a reference geometry, to evaluate the capture of process parameters and assess the impact of a traceability-informed adaptive strategy. Without WIM-based adaptivity, the test printing failed at 15-20 layers. With WIM-based adaptivity, the print was extended to 50-60 layers. The information model tracked the printing process, capturing robot/welder/sensor state data in a hierarchical, structured, and bidirectionally accessible format at a frequency of 2 Hz (every 500 ms). Throughout the testing, 1,555 individual adaptive points with calculated layer heights were captured. The developed model provides modularity, extensibility, and accessibility, enabling access to comprehensive WAAM process analysis in academic research.

Authors 3

1. Ethan Kerber corresponding Aachen Chair for Individualized Production (IP)

   RWTH Aachen University

   Affiliation as printed

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

2. Rahul Sharma Aachen Welding and Joining Institute

   RWTH Aachen University

   Affiliation as printed

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

3. Sigrid Brell‐Çokcan Aachen Chair for Individualized Production (IP)

   RWTH Aachen University

   Affiliation as printed

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