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Forming accuracy improvement in wire arc additive manufacturing (WAAM): a review

Yiwen Li (Shenyang University of Technology, Shenyang, China and Shenyang Collaborative Innovation Center Project for Multiple Energy Fields Composite Processing of Special Materials, Shenyang, China)
Zhihai Dong (Shenyang University of Technology, Shenyang, China and Shenyang Collaborative Innovation Center Project for Multiple Energy Fields Composite Processing of Special Materials, Shenyang, China)
Junyan Miao (Shenyang University of Technology, Shenyang, China and Shenyang Collaborative Innovation Center Project for Multiple Energy Fields Composite Processing of Special Materials, Shenyang, China)
Huifang Liu (Shenyang University of Technology, Shenyang, China)
Aleksandr Babkin (Lipetsk State Technical University, Lipetsk, Russian Federation)
Yunlong Chang (Shenyang University of Technology, Shenyang, China and Shenyang Collaborative Innovation Center Project for Multiple Energy Fields Composite Processing of Special Materials, Shenyang, China)

Rapid Prototyping Journal

ISSN: 1355-2546

Article publication date: 14 October 2022

Issue publication date: 4 April 2023

661

Abstract

Purpose

This paper aims to anticipate the possible development direction of WAAM. For large-scale and complex components, the material loss and cycle time of wire arc additive manufacturing (WAAM) are lower than those of conventional manufacturing. However, the high-precision WAAM currently requires longer cycle times for correcting dimensional errors. Therefore, new technologies need to be developed to achieve high-precision and high-efficiency WAAM.

Design/methodology/approach

This paper analyses the innovations in high-precision WAAM in the past five years from a mechanistic point of view.

Findings

Controlling heat to improve precision is an effective method. Methods of heat control include reducing the amount of heat entering the deposited interlayer or transferring the accumulated heat out of the interlayer in time. Based on this, an effective and highly precise WAAM is achievable in combination with multi-scale sensors and a complete expert system.

Originality/value

Therefore, a development direction for intelligent WAAM is proposed. Using the optimised process parameters based on machine learning, adjusting the parameters according to the sensors’ in-process feedback, achieving heat control and high precision manufacturing.

Keywords

Acknowledgements

The present research work was financially supported by Shenyang Collaborative Innovation Centre Project for Multiple Energy Fields Composite Processing of Special Materials (Grant No. JG210027), Shenyang Key Technology Special Project of “The Open Competition Mechanism to Select the Best Solution” (Grant No. 2022210101000827, 2022–0–43–048), the National Natural Science Foundation of China (Grant No. 51775354), Liaoning Revitalisation Talents Program (Grant No. XLYC2007072) and the Ministry of Education and Science of Russian Federation (Grant No.11.9505.2017/8.9).

Citation

Li, Y., Dong, Z., Miao, J., Liu, H., Babkin, A. and Chang, Y. (2023), "Forming accuracy improvement in wire arc additive manufacturing (WAAM): a review", Rapid Prototyping Journal, Vol. 29 No. 4, pp. 673-686. https://doi.org/10.1108/RPJ-05-2022-0154

Publisher

:

Emerald Publishing Limited

Copyright © 2022, Emerald Publishing Limited

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