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Related Experiment Video

Updated: Sep 20, 2025

Operation of the Collaborative Composite Manufacturing CCM System
10:09

Operation of the Collaborative Composite Manufacturing CCM System

Published on: October 1, 2019

6.7K

Collaborative Robotic Wire + Arc Additive Manufacture and Sensor-Enabled In-Process Ultrasonic Non-Destructive

Rastislav Zimermann1, Ehsan Mohseni1, Momchil Vasilev1

  • 1Centre for Ultrasonic Engineering, University of Strathclyde, Glasgow G1 1XW, UK.

Sensors (Basel, Switzerland)
|June 10, 2022
PubMed
Summary

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Angle-Dependent Terahertz Circular Dichroism and Full-Space Polarization Manipulation via Extrinsic Chiral Metasurfaces.

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This summary is machine-generated.

This study introduces a synchronized robotic system for Wire + Arc Additive Manufacturing (WAAM) and in-process Non-Destructive Evaluation (NDE). The system enables early defect detection during metal part fabrication, paving the way for in-process repairs and reducing scrap.

Area of Science:

  • Materials Science and Engineering
  • Manufacturing Technology
  • Robotics and Automation

Background:

  • The increasing demand for cost-efficient manufacturing of complex metal components fuels research in metal Additive Manufacturing (AM).
  • Wire + Arc Additive Manufacturing (WAAM) offers automated, time-, and material-efficient production of metal parts.
  • Current post-production Non-Destructive Evaluation (NDE) methods are often manual and inefficient, leading to costly rework or scrap.

Purpose of the Study:

  • To develop a synchronized multi-robot system for integrated WAAM and in-process NDE.
  • To enable real-time defect detection during the WAAM process.
  • To facilitate in-process repair and minimize wastage of defective builds.

Main Methods:

  • A synchronized multi-robot cell was designed for concurrent WAAM and NDE.
Keywords:
Wire + Arc Additive Manufacture (WAAM)in-process robotic NDEnon-destructive evaluationtotal focusing methodultrasound testing

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  • A novel high-temperature, dry-coupled phased array ultrasound transducer (PAUT) roller-probe was developed for NDE.
  • Real-time robot control based on sensor feedback enabled in-process inspection using Full Matrix Capture (FMC) and adaptive Total Focusing Method (TFM) imaging.

    • Main Results:

    • The integrated system successfully detected intentionally embedded reflectors (1.0 mm internal diameter tungsten tube) in a titanium WAAM sample.
    • Ultrasound data acquired in-process demonstrated a sufficient signal-to-noise ratio.
    • The developed approach shows potential for early defect identification within the WAAM process.

    Conclusions:

    • The synchronized robotic WAAM and NDE cell enables in-process defect detection.
    • The novel dry-coupled PAUT roller-probe is effective for high-temperature WAAM surfaces.
    • Early defect detection strengthens AM benefits by allowing for potential in-process repair, reducing scrap.