Improvement in process efficiency of waam-tig by in-situ voltage-current-temperature monitoring and feedback control system

Abstract

This research work explores the development and implementation of a temperature-dependent feedback control system for Wire Arc Additive Manufacturing Utilising Tungsten Inert Gas (WAAM-TIG). The primary objectives were to enhance process efficiency, control bead geometry, and mitigate overheating, a common challenge in multilayer deposition. A Proportional—Integral—Derivative (PID) controller was employed to maintain the melt pool temperature at a desired setpoint behind the deposition point, thereby regulating bead geometry and improving the overall quality of fabricated parts. The in-situ monitoring system ensured arc stability by adjusting input energy in real time, minimizing specific energy consumption and preventing overheating. This adaptive feedback control improved process efficiency by approximately 22%, enhancing WAAM-TIG deposition consistency. Notable enhancements in bead geometry were achieved, with the bead height increasing by 27.1% and the bead width decreasing by 14.7%. This resulted in improved geometrical uniformity, a critical factor in ensuring the dimensional accuracy of additively manufactured components. Despite these improvements in process efficiency and geometry, the system exhibited a negligible impact on the mechanical properties of the deposited material, including tensile strength, hardness, and resultant microstructure. The proposed control system enhances WAAM-TIG by ensuring real-time temperature regulation and arc stability, enabling reliable and efficient production. This advancement improves process control, promoting high-quality, energy-efficient, and precise metallic components for industrial applications.