Realisation of a multi-sensor framework for process monitoring of the wire arc additive manufacturing in producing Ti-6Al-4V parts
Realisation of a multi-sensor framework for process monitoring of the wire arc additive manufacturing in producing Ti-6Al-4V parts
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DOI：
10.1080/0951192x.2018.1466395
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发表时间：
2018-04
影响因子：
4.1
通讯作者：
Fang Xu;V. Dhokia;P. Colegrove;A. McAndrew;S. Williams;Andrew Henstridge;S. Newman
中科院分区：
文献类型：
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作者：
Fang Xu;V. Dhokia;P. Colegrove;A. McAndrew;S. Williams;Andrew Henstridge;S. Newman
电弧增材制造（WAAM）是一种基于电弧焊接的增材制造，它为航空航天工业提供了一个重要的机会，可以将购买飞行比从锻造和机加工的20：1降低到WAAM的5：1。WAAM方法可以在高沉积速度下从各种高级（金属）材料构建各种近净形状，而不需要昂贵的模具。然而，目前的WAAM方法和技术无法可靠地生产具有一致的结构材料特性和所需尺寸精度的零件。这是由于过程的复杂性和过程控制策略的缺乏。本文对WAAM或类似工艺中的监测方法进行了简要的综述。然后，作者确定的WAAM监控系统的基础上的过程的共同属性的要求。最后，实现了一种新型的多传感器框架，该框架监测系统电压/电流、零件轮廓和环境氧气水平。提出了一种新的信号处理技术，可以获得准确的电压和电流信号，消除随机噪声，从而大大提高WAAM的制造质量。
ABSTRACT Wire arc additive manufacturing (WAAM) is arc welding-based additive manufacture which is providing a major opportunity for the aerospace industry to reduce buy-to-fly ratios from 20:1 with forging and machining to 5:1 with WAAM. The WAAM method can build a wide range of near net shapes from a variety of high-grade (metallic) materials at high deposition speeds without the need for costly moulds. However, current WAAM methods and technologies are unable to produce parts reliably and with consistent structural material properties and required dimensional accuracy. This is due to the complexity of the process and the lack of process control strategies. This article makes a brief review on monitoring methods that have been used in WAAM or similar processes. The authors then identify the requirements for a WAAM monitoring system based on the common attributes of the process. Finally, a novel multi-sensor framework is realised which monitors the system voltage/current, part profile and environmental oxygen level. The authors provide a new signal process technique to acquire accurate voltage and current signal without random noises thereby significantly improving the quality of WAAM manufacturing.