Automated Interlayer Wall Height Compensation for Wire Based Directed Energy Deposition Additive Manufacturing.
Automated Interlayer Wall Height Compensation for Wire Based Directed Energy Deposition Additive Manufacturing.
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DOI：
10.3390/s23208498
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发表时间：
2023-10-16
期刊：
影响因子：
--
通讯作者：
Tatam R
中科院分区：
文献类型：
--
作者：
Qin J;Vives J;Raja P;Lasisi S;Wang C;Charrett T;Ding J;Williams S;Hallam JM;Tatam R
基于丝材的定向能量沉积增材制造（w-DEDAM）工艺中的零件质量监测和控制一直受到学术界和工业界的持续关注。然而，如计算机辅助设计（CAD）模型中所描绘的，保持一致的层高度并确保壁高度与设计紧密对齐，这构成了重大挑战。这些挑战是由于与制造过程和工作环境相关的不确定性而产生的，特别是在加工时间延长的情况下。为了在工业场景中实现这些目标，必须在整个零件制造过程中精确高效地测量沉积几何形状。此外，有必要了解基于各种工艺参数的层间沉积高度的变化。本文首先研究了当工艺参数在不同的壁区域内变化时，层间沉积高度的行为，特别关注过渡区域。此外，本文还探讨了几何监测信息在w-DEDAM构件建造过程中实施夹层墙高度补偿的潜力。使用相干距离分辨干涉法（RRI）传感器监测过程中的层高度，并仔细研究了这种测量的准确性和效率。利用这些信息和对沉积几何形状的理解，确定了工艺参数的控制点。随后，对每个壁区域应用适当且变化的工艺参数以逐渐补偿壁高度。壁高差异通常在两到三层中得到补偿。
Part quality monitoring and control in wire-based directed energy deposition additive manufacturing (w-DEDAM) processes has been garnering continuous interest from both the academic and industrial sectors. However, maintaining a consistent layer height and ensuring that the wall height aligns closely with the design, as depicted in computer-aided design (CAD) models, pose significant challenges. These challenges arise due to the uncertainties associated with the manufacturing process and the working environment, particularly with extended processing times. To achieve these goals in an industrial scenario, the deposition geometry must be measured with precision and efficiency throughout the part-building process. Moreover, it is essential to comprehend the changes in the interlayer deposition height based on various process parameters. This paper first examines the behaviour of interlayer deposition height when process parameters change within different wall regions, with a particular focus on the transition areas. In addition, this paper explores the potential of geometry monitoring information in implementing interlayer wall height compensation during w-DEDAM part-building. The in-process layer height was monitored using a coherent range-resolved interferometry (RRI) sensor, and the accuracy and efficiency of this measurement were carefully studied. Leveraging this information and understanding of deposition geometry, the control points of the process parameters were identified. Subsequently, appropriate and varied process parameters were applied to each wall region to gradually compensate for wall height. The wall height discrepancies were generally compensated for in two to three layers.
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