Kinematic weld-pool control for additive manufacturing with high-performance materials by gas tungsten arc welding

在节约资源和扩大轻量化结构战略方面，高性能材料的增材制造（AM）与钨惰性气体（TIG）焊接工艺在沉积速度和成本效益方面开辟了新的可能性。缺点是，该过程是非常有限的，考虑到组件的几何复杂性。该项目的目的是开发工件操作的新概念，以使复杂部件的生产过程不受限制。这种增材制造策略的一个重要组成部分是通过组件集成处理的方式进行运动学-电气熔池控制。焊接技术与机器人科学领域的跨学科融合是本项目的特色。通过对tig焊接增材生产的特征焊接路径的基本工艺分析，对熔池的运动学和焊接参数的行为有了深刻的理解。系统地存储参数空间，定义其极限并确定最佳参数配置。随后，将确定的数据用于创建预测模型，以便快速确定新的焊接路径和生产条件的参数。尤其重要的是运动和焊接过程的时间同步整体规划、优化和控制。使用一个复杂参考组件的示例验证了这些发现。在项目结束时，将获得一定程度的知识，使其能够迅速执行技术转让，从而取代以前的资源密集过程。

With regard to resource-saving production and expanded lightweight construction strategies, additive manufacturing (AM) of high-performance materials with the tungsten inert gas (TIG) welding process opens up new possibilities in terms of deposition rate and thus cost-effectiveness. The disadvantage is that the process is very limited with regard to the geometric complexity of the components. The aim of the project is to develop a new concept for work piece manipulation in order to enable a production process of complex components without restrictions. An essential component of this additive manufacturing strategy is kinematic-electrical melt pool control by means of component integrated handling. The interdisciplinary fusion of the scientific fields of welding technology and robotics is a characteristic feature of this project. By means of a fundamental process analysis of characteristic welding paths for additive production with the TIG-welding process, a profound understanding of the molten pool behaviour with regard to the kinematics and welding parameters is to be created. A parameter space is systematically stored, its limits defined and optimal parameter configurations determined. Subsequently, the determined data is used to create a predictive model for fast parameter determination for new welding paths and production conditions. Particularly important is the time-synchronous integral planning, optimization and control of the motion and welding process.These findings are validated using the example of a complex reference component. At the end of the project, a level of knowledge will be achieved that will enable the rapid implementation of a technology transfer and thus replace previous resource-intensive processes.