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Vision based process monitoring in wire arc additive manufacturing (WAAM)

Author

Listed:
  • Jan Franke

    (University of Passau)

  • Florian Heinrich

    (University of Passau)

  • Raven T. Reisch

    (Technical University of Munich (TUM)
    Siemens AG)

Abstract

A stable welding process is crucial to obtain high quality parts in wire arc additive manufacturing. The complexity of the process makes it inherently unstable, which can cause various defects, resulting in poor geometric accuracy and material properties. This demands for in-process monitoring and control mechanisms to industrialize the technology. In this work, process monitoring algorithms based on welding camera image analysis are presented. A neural network for semantic segmentation of the welding wire is used to monitor the working distance as well as the horizontal position of the wire during welding and classic image processing techniques are applied to capture spatter formation. Using these algorithms, the process stability is evaluated in real time and the analysis results enable the direction independent closed-loop-control of the manufacturing process. This significantly improves geometric fidelity as well as mechanical properties of the fabricated part and allows the automated production of parts with complex deposition paths including weld bead crossings, curvatures and overhang structures.

Suggested Citation

  • Jan Franke & Florian Heinrich & Raven T. Reisch, 2025. "Vision based process monitoring in wire arc additive manufacturing (WAAM)," Journal of Intelligent Manufacturing, Springer, vol. 36(3), pages 1711-1721, March.
    • Handle: RePEc:spr:joinma:v:36:y:2025:i:3:d:10.1007_s10845-023-02287-x
    DOI: 10.1007/s10845-023-02287-x
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    References listed on IDEAS

    as
    1. Haochen Mu & Joseph Polden & Yuxing Li & Fengyang He & Chunyang Xia & Zengxi Pan, 2022. "Layer-by-layer model-based adaptive control for wire arc additive manufacturing of thin-wall structures," Journal of Intelligent Manufacturing, Springer, vol. 33(4), pages 1165-1180, April.
    2. Jun Xiong & Yiyang Zhang & Yupeng Pi, 2021. "Control of deposition height in WAAM using visual inspection of previous and current layers," Journal of Intelligent Manufacturing, Springer, vol. 32(8), pages 2209-2217, December.
    Full references (including those not matched with items on IDEAS)

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