A study on power-controlled wire-arc additive manufacturing using a data-driven surrogate model

Abstract Wire-arc additive manufacturing (WAAM) provides an alternative for the production of various metal products needed in medium to large batch sizes due its high deposition rates. However, cyclic heat input WAAM may cause local overheating. To avoid adverse effects on performance part, interlayer dwelling and active cooling are used, but these measures increase process time. Alternatively, temperature during could be controlled by optimizing welding power. The present work aims at introducing implementing a novel management approach adjusting weld-bead cross-section along with power reduce accumulation process. evolution weld beads different cross-sections is investigated database relation between optimal pre-heating temperatures was established. numerical results validated experimentally block-shaped geometry. show that proposed method, test shape made welded lower energy consumption time as compared conventional constant-power WAAM. efficiently manages thermal reduces need pausing Hence, defects related might reduced, efficiency increased.