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

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.