Qin Jian, Vives Javier, Raja Parthiban, Lasisi Shakirudeen, Wang Chong, Charrett Thomas, Ding Jialuo, Williams Stewart, Hallam Jonathan Mark, Tatam Ralph
Welding and Additive Manufacturing Centre, Cranfield University, Cranfield MK43 0AL, UK.
WAAM3D Limited, Thornton Chase, Linford Wood, Milton Keynes MK14 6FD, UK.
Sensors (Basel). 2023 Oct 16;23(20):8498. doi: 10.3390/s23208498.
Part quality monitoring and control in wire-based directed energy deposition additive manufacturing (w-DEDAM) processes has been garnering continuous interest from both the academic and industrial sectors. However, maintaining a consistent layer height and ensuring that the wall height aligns closely with the design, as depicted in computer-aided design (CAD) models, pose significant challenges. These challenges arise due to the uncertainties associated with the manufacturing process and the working environment, particularly with extended processing times. To achieve these goals in an industrial scenario, the deposition geometry must be measured with precision and efficiency throughout the part-building process. Moreover, it is essential to comprehend the changes in the interlayer deposition height based on various process parameters. This paper first examines the behaviour of interlayer deposition height when process parameters change within different wall regions, with a particular focus on the transition areas. In addition, this paper explores the potential of geometry monitoring information in implementing interlayer wall height compensation during w-DEDAM part-building. The in-process layer height was monitored using a coherent range-resolved interferometry (RRI) sensor, and the accuracy and efficiency of this measurement were carefully studied. Leveraging this information and understanding of deposition geometry, the control points of the process parameters were identified. Subsequently, appropriate and varied process parameters were applied to each wall region to gradually compensate for wall height. The wall height discrepancies were generally compensated for in two to three layers.
基于线材的定向能量沉积增材制造（w-DEDAM）工艺中的零件质量监测与控制一直以来都备受学术界和工业界的持续关注。然而，要保持一致的层高，并确保壁高与计算机辅助设计（CAD）模型中所示的设计紧密对齐，面临着重大挑战。这些挑战源于制造过程和工作环境的不确定性，特别是在加工时间延长的情况下。为了在工业场景中实现这些目标，必须在整个零件制造过程中精确且高效地测量沉积几何形状。此外，理解基于各种工艺参数的层间沉积高度变化至关重要。本文首先研究了在不同壁区域内工艺参数变化时层间沉积高度的行为，特别关注过渡区域。此外，本文还探讨了几何形状监测信息在w-DEDAM零件制造过程中实施层间壁高补偿的潜力。使用相干距离分辨干涉测量（RRI）传感器监测过程中的层高，并仔细研究了这种测量的准确性和效率。利用这些信息以及对沉积几何形状的理解，确定了工艺参数的控制点。随后，对每个壁区域应用适当且不同的工艺参数，以逐步补偿壁高。壁高差异通常在两到三层中得到补偿。
