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<p>Wire Laser Directed Energy Deposition (WL-DED) offers significant advantages in the efficient and low-cost fabrication of complex metal components. However, issues such as heat accumulation and melt pool instability often lead to dimensional deviations and structural defects. To mitigate these challenges, this study proposes a feedforward–feedback (FF-FB) control strategy. The feedforward component incorporates an ARIMA time-series model to predict inter-layer melt pool temperature trends, enabling proactive thermal regulation. Simultaneously, a PID-based feedback loop ensures in-situ melt pool temperature correction. The method is validated through both offline prediction and physical experiments, and benchmarked against three control strategies: no control (Normal), feedback control (FB), and FF-FB. Results show that FF-FB control reduces vertical dimensional deviation by 99.27% (2.71&#xa0;mm) and improves structural uniformity by 89.26%. These improvements stem from the suppression of heat accumulation, enhanced thermal gradients, and stabilized melt pool dynamics. The proposed approach, with its low computational cost and strong real-time performance, demonstrates considerable potential for industrial adoption and offers a robust pathway toward quality improvement in WL-DED processes.</p>

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Thermal in-situ Monitoring and Predictive Control for Wire-Laser DED Using Feedforward–Feedback Coupling

  • 期刊论文

  • 发表日期：

    2025年8月29日

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  • Ruifang Ye,
  • Feng Chen,
  • Yi Li,
  • Chaofan Liu,
  • Yuhang Pan,
  • Zhenzhong Wang

摘要

Wire Laser Directed Energy Deposition (WL-DED) offers significant advantages in the efficient and low-cost fabrication of complex metal components. However, issues such as heat accumulation and melt pool instability often lead to dimensional deviations and structural defects. To mitigate these challenges, this study proposes a feedforward–feedback (FF-FB) control strategy. The feedforward component incorporates an ARIMA time-series model to predict inter-layer melt pool temperature trends, enabling proactive thermal regulation. Simultaneously, a PID-based feedback loop ensures in-situ melt pool temperature correction. The method is validated through both offline prediction and physical experiments, and benchmarked against three control strategies: no control (Normal), feedback control (FB), and FF-FB. Results show that FF-FB control reduces vertical dimensional deviation by 99.27% (2.71 mm) and improves structural uniformity by 89.26%. These improvements stem from the suppression of heat accumulation, enhanced thermal gradients, and stabilized melt pool dynamics. The proposed approach, with its low computational cost and strong real-time performance, demonstrates considerable potential for industrial adoption and offers a robust pathway toward quality improvement in WL-DED processes.