| Abstract Scope |
Wire Arc directed energy deposition (WA-DED) offers significant advantages for producing high-deposition-rate metal components, particularly for naval applications. However, achieving a CAD-to-part right at first time remains a challenge due to process variability and potential defect formation. Additional qualification challenges arise for naval applications from stringent certification requirements, corrosion resistance, mechanical performance in harsh environments, and repeatability across different builds. This work explores the integration of analytical modeling, process control, and real-time sensing to enhance the accuracy, repeatability, and qualification readiness of WA-DED for naval components. Predictive modeling enables preventative validation of the print strategy, allowing for optimized toolpaths before fabrication begins. Additionally, real-time thermal and geometric feedback enables precise layer-wise consistency and corrections (when needed), minimizing defects and inconsistencies within and between builds.
Embedding predictive modeling and process monitoring in WA-DED strengthens qualification efforts through improved traceability, data-driven defect detection, and consistent part quality. These advancements are critical for meeting stringent naval certification standards while reducing material waste and leadtimes, ensuring high-quality, certifiable components with minimal post-processing. |