Toward a smart wire arc additive manufacturing system: A review on current developments and a framework of digital twin

Comprehensive study of hot compression behaviors and microstructure evolution of solutionized 6082 aluminum alloy extruded bar

With the emergence of Industry 4.0, high productivity is critically dependent on robot manipulators. However, building an efficient and safe work environment with robot manipulators remains a challenge of hardware capability. The optimal path planning of the robot manipulator usually encounters shortcomings in low computational speed and tedious training after changing assembly lines and increases the risk during human–robot collaboration (HRC). To solve such a problem, we propose a path planning, named slice-based heuristic fast marching tree, based on joint space to achieve real-time path planning speed without modeling or training the workspace in advance. Our experimental results indicate that the time consumed for path planning in static environments is only from 0.51 s to 1.63 s, tested by a 6-DOF general-purpose industrial manipulator and different cylindrical obstacle placements. The time for path replanning in dynamic environments is from 0.62 s to 0.88 s. 

Collision avoidance and path planning for industrial manipulator using slice-based heuristic fast marching tree

Laser Wire-Feed Metal Additive Manufacturing (LWAM) is a process that utilizes a laser to heat and melt a metallic alloy wire, which is then precisely positioned on a substrate, or previous layer, to build a three-dimensional metal part. LWAM technology offers several advantages, such as high speed, cost effectiveness, precision control, and the ability to create complex geometries with near-net shape features and improved metallurgical properties. However, the technology is still in its early stages of development, and its integration into the industry is ongoing. To provide a comprehensive understanding of the LWAM technology, this review article emphasizes the importance of key aspects of LWAM, including parametric modeling, monitoring systems, control algorithms, and path-planning approaches. The study aims to identify potential gaps in the existing literature and highlight future research opportunities in the field of LWAM, with the goal of advancing its industrial application.

https://www.mdpi.com/1996-1944/16/5/2030/pdf?version=1677658848

Advancements in Laser Wire-Feed Metal Additive Manufacturing: A Brief Review

Directed energy deposition (DED) represents a pivotal advancement in intelligent manufacturing, facilitating efficient near-net shape metal part production, particularly suited for aerospace and defense applications demanding high precision. Arc-based DED relies on meticulous process and trajectory planning, where AI-driven manufacturing systems optimize paths and parameters to surmount intricate physical phenomena like material melting and heat transfer. AI methodologies such as deep learning and big data analytics offer promising solutions. The exclusive process planning software for DED-Arc (EPPS−DED) broadens the technology's application domains. This paper comprehensively outlines core algorithms pertinent to EPPS-DED and essential process strategies for meticulous process planning, providing insights for software development and part quality enhancement. Key topics covered include 3D model slicing, path planning, printing efficiency, and scanning order for 2D contours with diverse geometries, alongside strategies for inclined structures and lattices. Moreover, it discusses the latest AI applications in process planning. The paper concludes with current progress and future outlooks aimed at refining the accuracy and performance of DED-fabricated components. 

A comprehensive review of process planning and trajectory optimization in arc-based directed energy deposition

For the curved layer deposition with wire and arc additive manufacturing on complex surface, the molten pool behavior and bead geometry are variant at different welding positions for the dragging effect of gravity, which lead to inconsistent layer appearance. A region-based path planning method for robotic curved layer wire and arc additive manufacturing (CL-WAAM) is developed, with which all horizontal welding position can be maintained at arbitrary region of the complex surface. The adverse effect of gravity is minimized and uniform bead appearance can be guaranteed. Firstly, with a two-stage clustering method, the complex surface was divided into a certain number of simple subregions. Then, the contour line across cluster centroid of each subregion was employed as initial path, and an adaptive bead overlapping model changed with local inclined angle was used to generate the offset curved path covering the subregion. Therefore, the overall welding paths were approximate to the contour line on the surface, and the horizontal welding position and consistent forming appearance can be achieved. Finally, three surface parts were designed to validate feasibility of the method, and the forming appearance was compared with traditional iso-parametric method and flat layer WAAM (FL-WAAM). The results suggested that the surface waviness and thickness were relatively consistent at arbitrary region of complex surface with the region-based method, and the stair-step effect appeared in FL-WAAM was significantly alleviated with the CL-WAAM. The proposed method helps achieve the uniform layer appearance deposited on complex surface, which could be widely used in the manufacturing or repairing of wear-resistant surface parts, such as the hot forging die and hydraulic turbine blade.

Region-based path planning method with all horizontal welding position for robotic curved layer wire and arc additive manufacturing

Microstructural evolutions and mechanical properties of 6082 aluminum alloy part produced by a solution-forging integrated process

For the curved layer deposition with wire and arc additive manufacturing on complex surface, the molten pool behavior and bead geometry are variant at different welding positions for the dragging effect of gravity, which lead to inconsistent layer appearance. A region-based path planning method for robotic curved layer wire and arc additive manufacturing (CL-WAAM) is developed, with which all horizontal welding position can be maintained at arbitrary region of the complex surface. The adverse effect of gravity is minimized and uniform bead appearance can be guaranteed. Firstly, with a two-stage clustering method , the complex surface was divided into a certain number of simple subregions . Then, the contour line across cluster centroid of each subregion was employed as initial path, and an adaptive bead overlapping model changed with local inclined angle was used to generate the offset curved path covering the subregion. Therefore, the overall welding paths were approximate to the contour line on the surface, and the horizontal welding position and consistent forming appearance can be achieved. Finally, three surface parts were designed to validate feasibility of the method, and the forming appearance was compared with traditional iso-parametric method and flat layer WAAM (FL-WAAM). The results suggested that the surface waviness and thickness were relatively consistent at arbitrary region of complex surface with the region-based method, and the stair-step effect appeared in FL-WAAM was significantly alleviated with the CL-WAAM. The proposed method helps achieve the uniform layer appearance deposited on complex surface, which could be widely used in the manufacturing or repairing of wear-resistant surface parts, such as the hot forging die and hydraulic turbine blade. • A framework of robotic curved layer wire and arc additive manufacturing (CL-WAAM) was proposed. • A region-based path planning method with all horizontal welding position for the CL-WAAM was implemented. • The complex surface was subdivided into simple patches with a two-stage clustering method. • The contour line across the cluster centroid was employed as the initial path, with which the all horizontal welding position could be ensured. • The uniform forming appearance was achieved through the proposed region-based path planning method. 

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Region-based path planning method with all horizontal welding position for robotic curved layer wire and arc additive manufacturing

Microstructural evolutions and mechanical properties of 6082 aluminum alloy part produced by a solution-forging integrated process

Region-based path planning method with all horizontal welding position for robotic curved layer wire and arc additive manufacturing