Wire arc additive manufacturing with a gas metal arc welding configuration process as a heat source to deposit metal wire layer by layer, enabling the production of large and complex metal components with reduced material waste and lead time. However, this process is usually variable because the physics of the gas metal affects the wire retraction and their working rate. Consequently, the metal deposition could fail, changing the weld pool dimensions. Therefore, a monitoring system must check when these errors happen and alert their location for further corrections or to improve the welding process behaviour. In this scenario, this work aims to develop a data-driven monitoring system to, on the one hand, analyze the electrical signals to detect outliers that could affect the weld pool on its height or width. On the other side, a welding camera detects the contact-tip-working distance of the wire, which shows when the current of the welding arc changes during droplet growth. As a main result, the hybrid monitoring system alerts where the welding machine could fail when it is welding the material. In addition, the information from the welding camera was correlated with the electric pulses, validating outliers.

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A Hybrid WAAM Data-Driven Monitoring System to Correlate Electrical Signals with the Contact-Tip- Working-Distance

  • Paul D. Rosero-Montalvo,
  • Martin Martinez-Baltar,
  • Roi Méndez-Rial,
  • Félix Vidal-Vilariño

摘要

Wire arc additive manufacturing with a gas metal arc welding configuration process as a heat source to deposit metal wire layer by layer, enabling the production of large and complex metal components with reduced material waste and lead time. However, this process is usually variable because the physics of the gas metal affects the wire retraction and their working rate. Consequently, the metal deposition could fail, changing the weld pool dimensions. Therefore, a monitoring system must check when these errors happen and alert their location for further corrections or to improve the welding process behaviour. In this scenario, this work aims to develop a data-driven monitoring system to, on the one hand, analyze the electrical signals to detect outliers that could affect the weld pool on its height or width. On the other side, a welding camera detects the contact-tip-working distance of the wire, which shows when the current of the welding arc changes during droplet growth. As a main result, the hybrid monitoring system alerts where the welding machine could fail when it is welding the material. In addition, the information from the welding camera was correlated with the electric pulses, validating outliers.