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Automated Interlayer Wall Height Compensation for Wire Based Directed Energy Deposition Additive Manufacturing.

Jian Qin1, Javier Vives2, Parthiban Raja2

  • 1Welding and Additive Manufacturing Centre, Cranfield University, Cranfield MK43 0AL, UK.

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|October 28, 2023
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Summary
This summary is machine-generated.

This study addresses challenges in wire-based directed energy deposition additive manufacturing (w-DEDAM) by monitoring layer height. It demonstrates effective compensation for wall height discrepancies using process parameter adjustments, improving part quality.

Keywords:
interlayer wall height compensationpart quality monitoring and controlwire-based directed energy deposition additive manufacturing (w-DEDAM)

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Area of Science:

  • Materials Science and Engineering
  • Manufacturing Processes
  • Additive Manufacturing

Background:

  • Wire-based directed energy deposition additive manufacturing (w-DEDAM) faces challenges in maintaining consistent layer height and aligning wall height with CAD models.
  • Process uncertainties and environmental factors, especially during extended build times, contribute to these dimensional inaccuracies.
  • Precise and efficient in-process geometry measurement is crucial for industrial w-DEDAM applications.

Purpose of the Study:

  • To investigate the impact of process parameters on interlayer deposition height, particularly in transition areas of walls.
  • To explore the use of geometry monitoring data for real-time interlayer wall height compensation in w-DEDAM.
  • To improve dimensional accuracy and part quality in w-DEDAM.

Main Methods:

  • Utilized a coherent range-resolved interferometry (RRI) sensor for in-process monitoring of layer height.
  • Analyzed the behavior of interlayer deposition height across different wall regions and under varying process parameters.
  • Identified control points for process parameters based on geometry monitoring and deposition behavior.

Main Results:

  • Demonstrated the capability of RRI sensor for accurate and efficient in-process layer height measurement.
  • Successfully applied varied process parameters to specific wall regions to compensate for height discrepancies.
  • Achieved compensation for wall height discrepancies within two to three layers.

Conclusions:

  • Geometry monitoring information is valuable for implementing effective interlayer wall height compensation strategies in w-DEDAM.
  • Adaptive control of process parameters based on in-situ measurements can significantly enhance dimensional accuracy.
  • The developed approach offers a viable solution for improving part quality and consistency in industrial w-DEDAM.