519
Views
5
CrossRef citations to date
0
Altmetric
Review Article

Online monitoring of wire arc additive manufacturing process: a review

, , , , &
Pages 1412-1427 | Accepted 07 Mar 2023, Published online: 16 Mar 2023

References

  • Rosli NA, Alkahari MR, Ramli FR, et al. Influence of process parameters in wire and arc additive manufacturing (WAAM) Process. Journal of Mechanical Engineering (JMechE). 2020;17(2):69–78. DOI:10.24191/jmeche.v17i2.15301
  • Rosli NA, Alkahari MR, Ramli FR, et al. Design and Development of a Low-Cost 3d Metal Printer. Journal of Mechanical Engineering Research and Developments. 2018;41(3):47–54. DOI:10.26480/jmerd.03.2018.47.54
  • McAndrew AR, Alvarez Rosales M, Colegrove PA, et al. Interpass rolling of Ti-6al-4V wire + arc additively manufactured features for microstructural refinement. Additive Manuf. 2018;21:340–349.
  • Wu B, Pan Z, Ding D, et al. Effects of heat accumulation on microstructure and mechanical properties of Ti6Al4V alloy deposited by wire arc additive manufacturing. Additive Manuf. 2018;23:151–160.
  • Liu J, Xu Y, Ge Y, et al. Wire and arc additive manufacturing of metal components: a review of recent research developments. Int J Adv Manuf Technol. 2020;111(1–2):149–198. DOI:10.1007/s00170-020-05966-8
  • Zeng J, Nie W, Li X. The influence of heat input on the surface quality of wire and arc additive manufacturing. Appl Sci. 2021;11(21):10201.
  • Rosli NA, Alkahari MR, MFb A, et al. Review on effect of heat input for wire arc additive manufacturing process. J Mater Res Technol. 2021;11:2127–2145.
  • <Thermoelectric cooling-aided bead geometry regulation in wire and arc-based additive manufacturing of thin-walled structures.Pdf>.
  • Huang J, Yuan W, Yu S, et al. Droplet transfer behavior in bypass-coupled wire arc additive manufacturing. J Manuf Processes. 2020;49:397–412.
  • Nazan M, Ramli F, Alkahari M, et al. Process parameter optimisation of 3d printer response surface method. APRN Journal of Engineering and Applied Sciences. 2006;15:17.
  • Khaing MW, Fuh JYH, Lu L. Direct metal laser sintering for rapid tooling: processing and characterisation of EOS parts. J Mater Process Technol. 2001;113(1–3):269–272.
  • Malekipour E, El-Mounayri HD Mechanics of Additive and Advance Manufacturing. Volume 9: Proceedings of the 2017 Annual Conference on Experimental and Applied Mechanics; 2018. p. 83–90.
  • Xu F, Dhokia V, Colegrove P, et al. Realisation of a multi-sensor framework for process monitoring of the wire arc additive manufacturing in producing Ti-6al-4V parts. Int J Comput Integr Manuf. 2018;31(8):785–798. DOI:10.1080/0951192X.2018.1466395
  • Xia C, Pan Z, Polden J, et al. A review on wire arc additive manufacturing: monitoring, control and a framework of automated system. J Manuf Syst. 2020;57:31–45.
  • Li C, Liu ZY, Fang XY, et al. Residual stress in metal additive manufacturing. Procedia CIRP. 2018;71:348–353.
  • Gobert C, Reutzel EW, Petrich J, et al. Application of supervised machine learning for defect detection during metallic powder bed fusion additive manufacturing using high resolution imaging. Additive Manuf. 2018;21:517–528.
  • Sirin K, Sirin SY, Kaluc E. Influence of the interpass temperature on t 8/5 and the mechanical properties of submerged arc welded pipe. J Mater Process Technol. 2016;238:152–159.
  • Wu B, Pan Z, van Duin S, et al. Thermal behavior in wire arc additive manufacturing: characteristics, effects and control. Transaction on Intelligent Welding Manufacturing. 2019;2:3–18.
  • Jorge VL, Teixeira FR, Scotti A. Pyrometrical interlayer temperature measurement in WAAM of thin wall: strategies, limitations and functionality. Metals. 2022;12(5):765.
  • Montevecchi F, Venturini G, Grossi N, et al. Idle time selection for wire-arc additive manufacturing: a finite element-based technique. Additive Manuf. 2018;21:479–486.
  • Lehmann T, Jain A, Jain Y, et al. Concurrent geometry- and material-based process identification and optimisation for robotic CMT-based wire arc additive manufacturing. Materials & Design. 2020;194:108841.
  • Kozamernik N, Bračun D, Klobčar D. WAAM system with interpass temperature control and forced cooling for near-net-shape printing of small metal components. Int J Adv Manuf Technol. 2020;110(7–8):1955–1968.
  • Chabot A, Hascoët J-Y, Rauch M. Interest of process monitoring and numerical simulation to improve metallic additive manufacturing processes. AIP Conference Proceedings. 2019;2113:150002.
  • Yang D, Wang G, Zhang G. Thermal analysis for single-pass multi-layer GMAW based additive manufacturing using infrared thermography. J Mater Process Technol. 2017;244:215–224.
  • Gudur S, Nagallapati V, Pawar S, et al. A study on the effect of substrate heating and cooling on bead geometry in wire arc additive manufacturing and its correlation with cooling rate. Materials Today: Proceedings; Hydrabad, India; 2021;41:431–436.
  • Scotti A. The potential of IR pyrometry for monitoring interpass temperature in wire + arc additive manufacturing. Evolutions in Mechanical Engineering. 2019;3(1). DOI:10.31031/EME.2019.03.000553
  • Wu B, Ding D, Pan Z, et al. Effects of heat accumulation on the arc characteristics and metal transfer behavior in wire arc additive manufacturing of Ti6Al4V. J Mater Process Technol. 2017;250:304–312.
  • Font Comas T, Diao C, Ding J, et al. A passive imaging system for geometry measurement for the plasma arc welding process. IEEE Trans Ind Electron. 2017;64(9):7201–7209. DOI:10.1109/TIE.2017.2686349
  • Repossini G, Laguzza V, Grasso M, et al. On the use of spatter signature for in-situ monitoring of Laser Powder Bed Fusion. Additive Manuf. 2017;16:35–48.
  • Xiong J, Pi Y, Chen H. Deposition height detection and feature point extraction in robotic GTA-based additive manufacturing using passive vision sensing. Rob Comput Integr Manuf. 2019;59:326–334.
  • Xiong J, Shi M, Liu Y, et al. Virtual binocular vision sensing and control of molten pool width for gas metal arc additive manufactured thin-walled components. Additive Manuf. 2020;33:101121.
  • Yin Z, Xiong J. Stereovision measurement of layer geometry in wire and arc additive manufacturing with various stereo matching algorithms. J Manuf Processes. 2020;56:428–438.
  • Xiong J, Zhang G. Online measurement of bead geometry in GMAW-based additive manufacturing using passive vision. Meas SciTechnol. 2013;24(11):115103.
  • Wang Y, Zhang C, Lu J, et al. Weld reinforcement analysis based on long-term prediction of molten pool image in additive manufacturing. IEEE Access. 2020;8:69908–69918.
  • Xiong J, Zhang Y, Pi Y. Control of deposition height in WAAM using visual inspection of previous and current layers. J Intell Manuf. 2020;32(8):2209–2217.
  • Xiong J, Yin Z, Zhang W. Closed-loop control of variable layer width for thin-walled parts in wire and arc additive manufacturing. J Mater Process Technol. 2016;233:100–106.
  • Xiong J, Zhang G, Qiu Z, et al. Vision-sensing and bead width control of a single-bead multi-layer part: material and energy savings in GMAW-based rapid manufacturing. J Clean Prod. 2013;41:82–88.
  • Wang X, Wang A, Li Y. An online surface height measurement method for GTAW-based additive manufacturing. Weld world. 2019;64(1):11–20.
  • Xia C, Pan Z, Zhang S, et al. Model predictive control of layer width in wire arc additive manufacturing. J Manuf Processes. 2020;58:179–186.
  • Lin W, Shen H, Fu J, et al. Online quality monitoring in material extrusion additive manufacturing processes based on laser scanning technology. Precis eng. 2019;60:76–84.
  • Sitthi-Amorn P, Ramos JE, Wangy Y, et al. Machine vision assisted platform for multi-material 3D printing. ACM Transactions on Graphics. 2015;34(4):1–11. DOI:10.1145/2766962
  • Wu Y, He K, Zhou X, et al. Machine vision based statistical process control in fused deposition modelling. Proceedings of the 2017 12th IEEE Conference on Industrial Electronics and Applications, ICIEA 2017; 2018 February; Siem Reap, Cambodia; p. 936–941.
  • Shen H, Sun W, Fu J. Multi-view online vision detection based on robot fused deposit modeling 3D printing technology. Rapid Prototyping J. 2019;25(2):343–355.
  • Lu L, Zheng J, Mishra S. A Model Based Layer to layer control algorithm for inkjet 3D printing. Proceedings of the ASME 2014 Dynamic Systems and Control Conference. San Antonio, Texas, USA; 2014;46193:V00T35A001.
  • Heralić A, Christiansson A-K, Lennartson B. Height control of laser metal-wire deposition based on iterative learning control and 3D scanning. Opt Lasers Eng. 2012;50(9):1230–1241.
  • Faes M, Abbeloos W, Vogeler F, et al. L-arginine affects the IVM of cattle cumulus-oocyte complexes. Theriogenology. 2016;88:134–144.
  • Rebaioli L, Magnoni P, Fassi I, et al. Process parameters tuning and online re-slicing for robotised additive manufacturing of big plastic objects. Rob Comput Integr Manuf. 2019;55:55–64.
  • Han Q, Li Y, Zhang G. Online control of deposited geometry of multi-layer multi-bead structure for wire and arc additive manufacturing. Transaction on Intelligent Welding Manufacturing. 2018;1:85–93.
  • Xiong J, Y-J L, Yin Z-Q, et al. Determination of surface roughness in wire and arc additive manufacturing based on laser vision sensing. Chin J Mech Eng. 2018;31:1–7.
  • Suárez A, Aldalur E, Veiga F, et al. Wire arc additive manufacturing of an aeronautic fitting with different metal alloys: from the design to the part. J Manuf Processes. 2021;64:188–197.
  • Aldalur E, Veiga F, Suárez A, et al. High deposition wire arc additive manufacturing of mild steel: strategies and heat input effect on microstructure and mechanical properties. J Manuf Processes. 2020;58:615–626.
  • Hauser T, Reisch RT, Breese PP, et al. Oxidation in wire arc additive manufacturing of aluminium alloys. Additive Manuf. 2021;41:101958.
  • Zhao Z, Guo Y, Bai L, et al. Quality monitoring in wire-arc additive manufacturing based on cooperative awareness of spectrum and vision. Optik. 2019;181:351–360.
  • Tang S, Wang G, Song H, et al. A novel method of bead modeling and control for wire arc additive manufacturing. Rapid Prototyping J. 2021;2(August 2020):311–320. DOI:10.1108/RPJ-05-2020-0097
  • Geng H, Xiong J, Huang D, et al. A prediction model of layer geometrical size in wire and arc additive manufacture using response surface methodology. Int J Adv Manuf Technol. 2015;93(1–4):175–186. DOI:10.1007/s00170-015-8147-2
  • Pringle AM, Oberloier S, Petsiuk AL, et al. Open source arc analyser: multi-sensor monitoring of wire arc additive manufacturing. HardwareX. 2020;8:e00137.
  • Artaza T, Alberdi A, Murua M, et al. Design and Integration of WAAM technology and in situ monitoring systems in a gantry machine. Procedia Manuf. 2017;13:778–785.
  • Ščetinec A, Klobčar D, Bračun D. In-process path replanning and online layer height control through deposition arc current for gas metal arc based additive manufacturing. J Manuf Processes. 2021;64:1169–1179.
  • Richter A, Gehling T, Treutler K, et al. Real-time measurement of temperature and volume of the weld pool in wire-arc additive manufacturing. Measurement: Sensors. 2021;17:100060.

Reprints and Corporate Permissions

Please note: Selecting permissions does not provide access to the full text of the article, please see our help page How do I view content?

To request a reprint or corporate permissions for this article, please click on the relevant link below:

Academic Permissions

Please note: Selecting permissions does not provide access to the full text of the article, please see our help page How do I view content?

Obtain permissions instantly via Rightslink by clicking on the button below:

If you are unable to obtain permissions via Rightslink, please complete and submit this Permissions form. For more information, please visit our Permissions help page.