Vision-Based Estimation of Force Balance of Near-Suspended Melt Pool for Drooping and Collapsing Prediction

Wire-arc additive manufacturing (WAAM) is favored by the industry for its high material utilization rate and low cost. However, wire-arc additive manufacturing of lattice structures faces problems with forming accuracy such as broken rod and surface morphology defects, which cannot meet the industrial demand. This article innovatively combines the melt pool stress theory with visual perception algorithms to visually study the force balance of the near-suspended melt pool to predict the state of the melt pool. First, the method for melt pool segmentation was studied. The results show that the optimized U-net achieved high accuracy in melt pool segmentation tasks, with accuracies of 98.18%, MIOU 96.64%, and Recall 98.34%. In addition, a method for estimating melt pool force balance and predicting normal, sagging, and collapsing states of the melt pool is proposed. By combining experimental testing with computer vision technology, an analysis of the force balance of the melt pool during the inclined rod forming process was conducted, showing a prediction rate as high as 90% for the testing set. By using this method, monitoring and predicting the state of the melt pool is achieved, preemptively avoiding issues of broken rods during the printing process. This approach can effectively assist in adjusting process parameters and improving welding quality. The application of this method will further promote the development of intelligent unmanned WAAM and provide some references for the development of artificial intelligence monitoring systems in the manufacturing field.