Advanced multi-sensor monitoring system in wire arc additive manufacturing for enhanced process and parts production

Abstract

Wire Arc Additive Manufacturing (WAAM) is a Directed Energy Deposition (DED) technology widely recognized for its capability to produce large-scale components, repair damaged parts, and achieve high deposition rates. Among WAAM processes, the Cold Metal Transfer (CMT) technique has garnered significant attention due to its low heat input and stable short-circuiting behavior, resulting in reduced spatter and enhanced control. This study aims to develop robust monitoring strategies to evaluate process quality and detect potential anomalies during the WAAM-CMT process. Single tracks of ER70S-6 steel were deposited, and a comprehensive monitoring system was implemented, incorporating two types of MEMS accelerometers and a digital microphone to capture acceleration, vibration, and acoustic emissions during the printing process. The proposed approach demonstrated its effectiveness in identifying potential defects and anomalies, contributing to the early detection of process instabilities. The findings provide a reliable framework for real-time monitoring and quality assurance in WAAM applications, highlighting the potential of sensor-based methodologies to enhance manufacturing outcomes.