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About this Abstract
Meeting 2025 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2025)
Symposium 2025 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2025)
Presentation Title Numerical Modelling of Thermal Predictions in Wire-Arc Additive Manufacturing for Online Implementations
Author(s) Kathryn Kelly, Andrew Hill, Christopher Saldana, Kyle Saleeby
On-Site Speaker (Planned) Kathryn Kelly
Abstract Scope Robotic wire-arc additive manufacturing (R-WAAM) has experienced greater industry adoption due to its balance of cost and flexibility in additive manufacturing. While existing numerical thermal models have been established for traditional gas-metal arc welding (GMAW) methods, no such model has been created utilizing aluminum and the lower heat-input cold metal transfer (CMT) process. These models use external software, making them less suited for implementation in online control methods. In this work, a Python-based thermal model is presented that uses the thermal constants of aluminum and experimentally determined inputs to create a simulation that is accurate for individualized systems with the increasing part scale that R-WAAM is capable of. Simulation predictions had a mean error of 10% with an improvement of 6-15% over deposition time. This thermal model can be implemented in future work as part of an online control schema supporting temperature sensors where readings may be inaccessible.
Proceedings Inclusion? Planned: Post-meeting proceedings

OTHER PAPERS PLANNED FOR THIS SYMPOSIUM

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3D Surrogate Modeling of Elasto-Viscoplastic FFT Simulations for Porosity-Driven Fatigue Prediction in Additive Manufacturing
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A Dual Nozzle Approach to Balancing Fill Speed and Detail Accuracy in Polymer MEXAM Systems
A FE Based Global-Submodel Simulation Approach for Shape Compensation and Predicting Failure in Metal Parts Fabricated by Laser Powder Bed Fusion
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A Machine Learning Model to Predict Mechanical Property of Directed Energy Deposition Processed Low Alloy Steels
A Method for Improving the Build Time During Wire Arc Based Directed Energy Deposition of Low Carbon Steel
A Novel Additive Manufacturing Approach for the Freeform Deposition of Polymer Matrix Composites With Laser Induced Curing
A Novel Slicing Algorithm for Wall Structures for Additive Construction
A Parametric Workflow for Brazing-Ready, Self-Supporting Metal AM Components With Recoverable Features
A Predictive Approach to Estimating Build time and Material Usage Through an Intuitive Design for Additive Manufacturing Score
A Study of Hybrid Additive Manufacturing Processes for High Melting Point Materials Using Powder Metallurgy
A Test Artifact for Rapid Evaluation of Material Ductility Variation in Laser Powder Bed Fusion
Accelerated Cooling Strategy to Shorten Build Time in Wire-DED of Inconel 625
Accelerating Laser Powder Bed Fusion Microstructure Simulations
Accurate Alignment of Metal Binder Jetted Part Assemblies
Accurate Detection of Local Porosity in Laser Powder Bed Fusion Through Deep Learning of Physics-Based In-Situ Infrared Camera Signatures
Achieving Sub-Pixel Level Feature Size for Projection Stereolithography via Precise Spatial and Temporal Control of Photopolymerization
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Analytical Prediction of Optimized Processing Parameters in Metal Additive Manufacturing
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Anomaly Detection in UR5 Robots Using Reinforcement Learning for Smart Manufacturing
Application of Scientific Machine Learning Techniques to Metal Additive Manufacturing Simulation: A Comparison Between Physics-Informed Neural Networks and Extended Physics-Informed Neural Networks
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Blow Extrusion 3D Printing of Variable Hollow Structures for High-Throughput Material Extrusion
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Cold Isostatic Pressing of Additively Manufactured Poly(tetrafluoroethylene): A Post-Process to Eliminate Printing Defects and Enhance Mechanical Properties
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Computational Fluid Dynamics Modeling and Experimental Analysis of Rapid Curing in 3D Printing for Structural Applications
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Conditional Variational Autoencoder Framework for Geometric-Constrained, Nonlinear Property-Driven Composite Microstructure Design
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Data-Driven Geometry Classification for Manufacturing Process Planning
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Data-Efficient Bayesian Optimization for Layer-wise Dimensional Accuracy Control in Directed Energy Deposition
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Deep Learning-Based Printing Defects Detection in Fused Filament Fabrication Process
Deformation Control in Wire Arc Additive Manufacturing via a Secondary Heat Source
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Design and Additive Manufacturing of Multifunctional Materials With Intrinsic Sensing and Morphological Computing
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Design, Manufacture and Testing of Structural Trusses Using Additively Manufactured Polymer Composites
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Effect of Particle Size on Optical Properties of Powder Bed With Near-Infrared Laser for Large Scale Powder Bed Fusion Process in Polymer
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Evaluation of Temporal Stability and Device-to-Device Variability in Aerosol Jet Printed Electrodes
Evaluation of the Thermal Properties of Clay Reinforced With Polymer and Biomass Residue for Structural Application
Examining Composition Effect on Thermal History in Laser Powder Bed Fusion of Alloy 718
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Experimental Validation and Calibration of Computationally Efficient Mesoscale Microstructure Model for LPBF-Processed Ti-6Al-4V
Experimental Validation of FE Substrate Deflection Predictions in Wire-Arc DED Using Strain Gauges and Laser Displacement Sensors
Exploring the Functional Performance of a Commercial High-Temperature Photopolymer Resin for Vat Photopolymerized Injection Molding Tools
Fabrication of SiC–Al Composites via Binder Jetting 3D Printing and Infiltration: Effects of Sintering Temperature and Time
Fatigue-Induced Interbead Void Evolution in Additively Manufactured Polymers
FDM-based Copper/Polymer Composites for Custom Thermal Components
Feasibility Study on a 2-Step Curing Process to Manufacture Dielectric and Electrically Conductive Materials
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From Solid-to-Solid Manufacturing Strategy for High-Performance Solid State Li-ion Battery
Functionally Graded TPMS Lattice Structures Optimized to Improve Mechanical Performance for Biomedical Applications
Functionally Inspired Part-Structure-Process Qualification Artifact for Laser Powder Bed Fusion AM With Feature-Specific Metrology, Standardization, and In-Situ Monitoring
Generative Adversarial Networks for Topology Optimization With Orientation
Geometry-Agnostic EBM Parameters via Freeform Scan Paths
Heterogeneity and Distortion in Shelled Binder Jet Geometries in Green and Sintered Parts
Hybrid Additive-Subtractive Manufacturing of Ti-5Al-5Mo-5V-3Cr Using Laser Powder Bed Fusion for Complex Geometries
Hybrid Joining of Additively Manufactured 316L Stainless Steel via Friction Welding: Mechanical and Microstructural Insights
Hybrid Reinforcement Learning and Neural Network Framework for Optimizing Deposition Paths and Thermal Profiles in Solid Freeform Fabrication of Functionally Graded Materials Using Maxel (Material Voxel) Framework
Hybrid Sensor in the Loop Approach for Generating Synthetic Event Imager Data of Melt Pool Dynamics
Hybridization of Commercial Directed Energy Deposition System for In-Situ Repair of Parts
Hydrothermal-Assisted Jet Fusion: A Selective Cold Sintering Approach
Identification of Stochastic Manufacturing Defects Within Additively Manufactured Acoustic Liners
Impact of In-Spec Composition Variation of TiAl6V4 on Martensite Decomposition
Impact of Layer Orientation on Radio Frequency Dielectric Properties of Fused Filament Fabricated ULTEM 9085
Implicit Modeling-Based Feature Extraction and Optimization Framework for Additive Manufacturing
Improving Dimensional Accuracy in PBF-LB/M: A Method for Process Parameter Adaption and Beam Offset Correction
Improving Powder Spreading and Compaction for Selective Laser Flash Sintering
Improving the Mechanical Properties of 3D Printed Polypropylene/Carbon Fiber Parts Made By Fused Deposition Modeling (FDM) Technology
In-situ Annealing and Thermal-Morphological Insights for Improving Mechanical Properties of FFF-Printed ABS
In-Situ Determination of Powder-Laser Focus Overlap in High-Speed DED Using Multispectral Emission Analysis
In-Situ Femtosecond Micromachining in Laser Powder Bed Fusion Processes
In-Situ Gas-Phase Nanoparticle Synthesis During Directed Energy Deposition of Metallic Alloys
In-Situ Measurements of Selective UV Photocuring Using X-Ray Photon Correlation Spectroscopy for Vat Photopolymerization Additive Manufacturing
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In-Situ Prediction of Flaw Formation and Microstructure in Laser Powder Bed Fusion Using Physics and Data-Driven Machine Learning
Increased Spatial Resolution With a Single Nozzle in Fused Filament Fabrication Through Controlled Distributions and Volume Fractions of Soluble and Insoluble Materials Including Formation of Functionally Graded Lattices
Influence of Bead Width and Layer Time on the Interlayer Bonding of Large-Format Printed Polymer Composites
Influence of Melt Pool and Wire Behavior on Process Stability in Hot Wire Directed Energy Deposition
Influence of Pulsed Waveform Duration and Shape on Droplet-on-Demand Metal Jetting Stability
Innovative Gaseous Treatment and Foam Extrusion System for Large-Scale Additive Manufacturing Applications
Integrated Computational-Experimental Framework for Additive Manufacturing and Post Processing of Functionally Graded Materials from Structural to Refractory Alloys
Intelligent Quality Management in Additive Manufacturing: Leveraging Big Data, Multi-Scale Fusion, and Digital Twins
Interfacial Interaction of a Bi-Material Copper-D2 Tooling Steel Structure Manufactured Using a Blue Laser Hybrid Direct Energy Deposition Process
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Investigating Surface Affinity for the Deposition of Metal-Organic Decomposition Inks in a Vat
Investigation of Drop Mass Deviations in MMJ Systems During Part Printing
Investigation of Molten Metal Jetting With Salt Support Structures via an Automated Multi-Material Simulation Framework
Investigation of the Surface Roughness of Micromilled 316L Stainless Steel Fabricated by FDM/FFF Technology
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Laser Induced Breakdown Spectroscopy for Material Identification in Laser Powder Bed Fusion Processing
Laser Powder Bed Fusion of NiTi: Compositional Effect
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Location-Based Structure-Property Relationships of Laser Powder Bed Fusion(L-PBF) Inconel 718 Parts
Low-Cost 3D Scanning for Wire Arc Additive Manufacturing
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Low-Cost Two-Color Pyrometry in Laser Powder Bed Fusion
Machine-Learning-Based Inverse Design of Multi-Material Curved Lattice Structures
Machine Learning-Based Optimisation to Design Truss and Plate-Based Multi-Functional Metamaterials
Machine Learning-Based Prediction of Toughness in Fused Filament Fabrication: Leveraging In-Process Annealing With Enhanced Printheads
Machine Learning Based Evaluation of Surface Roughness of Additively-Manufactured Nylon 12 Surgical Guides
Mechanical Behavior of an Additively Manufactured Psuedoelastic Nitinol
Mechanical Performance and Internal Porosity of 3D Printed PLA Across Varying Parameters
Mechanical Performance and Weight Reduction of Additively Manufactured Titanium Bolts Aimed for Supply Chain Resiliency of Critical Material
Micro-/Defect-Structure Characterization of Additively Manufactured Metallic Parts Using Laboratory Diffraction Contrast Tomography
Microstructure-Driven Fracture Behavior and Thermo-Mechanical Analysis of Large Area Additive Manufactured Short Fiber Composites
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Mixing Tungsten With Inconel 718: Effects on Energy Density and Material Properties in 3D Printing
Modeling and Simulation of Cold Spray Additive Manufacturing: Insights Into Metallic Particle Bonding
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Multi-Material Inkjet Print Deposition of Particle-Free Silver and Molecular-Organic-Decomposition Nickel Inks for High Temperature Conductive Circuit Thermal Shielding
Multi-Material, High-Viscosity Vat Photopolymerization
Multi-Nozzle Molten Metal Jetting With Variable Nozzle Pitch
Multi-Sensor Process Monitoring for Blue Laser Directed Energy Deposition of Copper
Multimaterial Aerosol Jet Printing of Memristors on Flexible Substrates
Multimaterial and Isotopically Labeled Specimen Fabrication via Material Extrusion Additive Manufacturing for Interlayer Diffusion Analysis
Multiphysics Modeling to Assess the Powder Bed Characteristics of Inconel 718 for a Circular Substrate in Laser Powder Bed Fusion
Neural Network Prediction of Printing Parameters and Solar Absorptivity via Powder Bed Fusion
Node-Based Closed-Loop Control in Robotic Laser-Wire Directed Energy Deposition
Numerical Analysis of Pre- and Post-Heating Strategies for Reducing Residual Stresses in Laser-Based Directed Energy Deposition
Numerical Modelling of Thermal Predictions in Wire-Arc Additive Manufacturing for Online Implementations
Omnidirectional Laser Metal Deposition with Wire (LMD-w) for 6 Feet and Larger Aerostructures
On Calibration Procedures and Powder Deposition Uncertainty of a Multi-Material Laser Powder Bed Fusion Machine
On the Time Integration for Phase Field Modeling of Grain Growth in Additive Manufacturing
Opening the Design Space, why Does Multi-Functional Additive Manufacturing Matter?
OpenVCAD in Practice: Streamlined Multi-Material Design and Fabrication
Optical Frequency Domain Reflectometry (OFDR) on Fiber Embedded Metal Parts Created with Laser Powder Bed Fusion
Optimizing LPBF for MMCs: Effects of Reduced Powder and Laser Spot Sizes on Reinforcement Distribution, Microstructure, and Mechanical Performance
Oxygen Saturation as a Strategy to Mitigate User-Induced Variation in Tomographic Volumetric Additive Manufacturing
Packing Fraction Sensing in Metal Binder Jetting Using Airborne Ultrasound Transducer
Photoelastic Visualization of Residual Stresses in PLA After Interlayer Shot Peening During Fused Filament Fabrication
Physics-Aware AI for Born-Qualified Additive Manufacturing: Toward Real-Time, In-Situ Part Qualification
Physics-Guided Thermal History Control to Improve Part Quality in Laser Powder Bed Fusion Additive Manufacturing
Polymer AM Part Thermal History From In-Situ Thermal Data and Heuristic Modeling
Pore Behavior in Melt Pool Properties Based on Ti-6Al-4V and SS316L Powders in Directed Energy Deposition (DED) Processes
Porosity Reduction in Large-Format Additive Manufacturing of Fiber-Reinforced Composites via Elongational Screw Design
Porous Membranes for Controlled Release Profiles using Stereolithography and Phase Separation
Post-Build CT Segmentation and Alignment with L-PBF In-Situ Monitoring Signatures
Powder Bed Interaction with Higher Translation Speed Electron Beams Path for the Area Printing
Powder Dispersion For Removal of Unsintered Powder After Selective Laser Flash Sintering
Powder Flow Dynamics in Laser Metal Deposition
Powder Particle Impact Behavior in Laser, Powder-Blown Directed Energy
Predicting LPBF Ti-6Al-4V Microstructure via Multi-Modal In-Situ Process Monitoring
Predicting Melt Pool Dimensions from Local Thermal Environment Through a Modified Rosenthal Solution
Predicting Microstructure Properties Using Transfer Learning for Microscale Selective Laser Sintering (μ-SLS)
Predicting the Solidified Microstructure in Laser Powder Bed Fusion (LPBF) of Inconel 718 using Physics-Based Modeling and In-situ Sensor Data
Prediction of Failure in Additively Manufactured Metallic Components
Predictive Modeling of Particle Loading for Functional Grading in Reactive Extrusion Additive Manufacturing
Predictive Qualification of Laser Powder Bed Fusion: Leveraging Multi-Modal In-Situ Monitoring and Real-Time Control for Part Qualification
Printing Cryomilled Copper Chips by Blue Laser Directed Energy Deposition (DED)
Process-Aware Topology Optimization for Mitigating Residual Stress and Distortion in Laser Powder Bed Fusion
Process Mapping for Single-Track Laser Wire Additive Manufacturing of AZ31 Magnesium Alloy
Producing Stochastic Metal Foam on Desktop FFF 3D Printers using Viscous Thread Printing
Pulsed Arc Additive Manufacturing of a Duplex Stainless Steel and HSLA Functionally Graded Material
Pushing the Frontier of Computational Design Leveraging Machine Learning (ML)
Qualification of Laser-Based Powder Bed Fusion of Metals (PBF-LB/M) Using Scanner Data
Quantifying Machine-Induced Error in a Custom Binder Jet Platform for Radio Frequency Additive Manufacturing
Quantifying the Dynamic Properties of 3D Printed Polymers and Polymer Composites Via Ultrasonics
Radiative Property Characterization of Porous Medium Using Liquid-Based Advanced Micro-Additive Manufacturing Technique
Rapid and Non-Contact Density Measurement for Powder-Based AM Via Flash Thermography
Rapid Direct-Write Printing of Metallic Nanostructures Via In-Flight Plasma Reduction
Real-Time Closed-Loop Control for Precision Liquid Metal Jetting
Real-Time Implementability Evaluation of FPGA-Based Trackwise Model Predictive Control for Laser Powder Bed Fusion
Real-Time Prediction of Working Distance in Laser-Wire DED Via Multi-Modal In-Situ Data Fusion Using a CNN Model
Real Time Measurement System for Digital Glass Shaping Processes
Real Time Vision-Based Morphology Tracking of Glass Additive Manufacturing Processes
Regolith-Filled Thermoset as a Candidate Material in Lunar Construction
Repurposing, Reusing, and Recycling Metal Feedstocks for Laser Additive Manufacturing
Review on Atomization of Metals
Rheology-Driven Analysis of Extrusion Forces in Fused Filament Fabrication
Rheology-Informed Mixture Engineering of Aggregates for Extrusion Additive Manufacturing
Rheology Modification and Reinforcement of True Silicone Resins for Vat Photopolymerization
Robotic Wire Arc DED (Directed Energy Deposition) of 316 l Stainless Steel Preform for Forging Preforms
Role of Defect Interaction and Multi-Site Damage in Fatigue Life of Additively Manufactured Metals
Room Temperature Mechanical Behavior of Monel K500 Alloy Fabricated via L-PBF and LP-DED
Route Your Ooze (RYO) Drive: A New Way to Route Flexible Filament in 3D Printing with Motion-Decoupled Rolling Joints
Sacrificial Preform Design and Parameter Optimization for Thin Walls and Corners in Powder-Blown Hybrid DED
Scalable and Data-Driven Control Strategy for Layer Thickness Consistency in Directed Energy Deposition
Scalable Thermal Surrogate Modeling for LPBF Using STEAM
Selective Laser Etching of Fused Silica for Complex 3D Geometries
Shape Optimization and Sensitivity Analysis for Triply Periodic Minimal Surface Lattice Structures Under Periodic Boundary Conditions
Silicon Carbide Nanoparticle Filled Nanocomposites Using SLA Resin for Low Thermal Expansion and Enhanced Mechanical Properties
Simultaneous Time Resolved SAXS and WAXS Characterization for Laser Additive Manufacturing via X-Ray Pump Probe at LCLS X-Ray Free Electron Lasers
Slit Accuracy of Thin Walls in Laser Powder Bed Fusion
Small-Scale Meta Structures Additively Manufactured from an Alumina Forming Austenitic Stainless Steel
SMOS Hub: Enabling Autonomous Cooperation in Heterogeneous Manufacturing Swarms
Spatiotemporal Laser Beam Shaping for Topographical Control in Laser Powder Bed Fusion
STEAM: A Scalable Surrogate Modeling Framework for Scanwise Thermal Simulation in Laser Powder Bed Fusion
Stress-Corrosion Behavior of Magnesium Alloy AZ91 Manufactured by Laser Powder Bed Fusion
Study of Fatigue Endurance on Artificially Aged Additive Manufactured AlSi10Mg After Stress Relived and Hot Isostatic Pressed + T6
Surface Correction Process Development for 410 SS Deposited with Wire Arc Additive Manufacturing
Synchronized, Multi-Mode Process Monitoring for Wire Arc Additive Manufacturing
Systematic Evaluation of Classical and Adaptive Control Strategies for Gantry - Positioning Reliability in FDM Additive Manufacturing
Tailoring Binder Jet Green and Sintered Part Strength Through Architected Infills
Tailoring Ceramic Slurry Behavior Through Binder Variation: A Three-System Study
Temperature Control in Volumetrically Heated Digital Glass Forming
Temperature Sensor Comparison Study of Spot Pyrometers and Contact Thermocouples for Improved Thermal Monitoring of Wire-Arc DED
The Alloy Optimization Software (TAOS)
The Effects of Gravity on Track Integrity During Collaborative Robot-Assisted Wire Arc Additive Manufacturing
The Future of 3DP+
The Influence of Hot Isostatic Pressing Process on the Fatigue Life of EB-PBF Printed Ti-6Al-4V
Thermal Monitoring in AC Selective Laser Flash Sintering of Ceramics Using a Mid-Wave Infrared Photodiode
Toolpath Planning for Multi-Nozzle Concurrent Molten Metal Jetting Process
Top Layer Quality Assurance of Complex Geometries Based on Region of Interest in Additive Manufacturing
Topology and Orientation Optimized-Inspired Toolpath Planning for Continuous Fiber Material Extrusion
Toward Real-Time Finite Element Analysis-Informed Feedback Control of Wire-Arc Directed Energy Deposition via Robot Operating System 2 In-Situ Monitoring System
Towards Parametric Design for Additive Manufacturing of Coral Structures Using a Digital Twin Approach
Towards the Production of a 3D Part in Selective Laser Additive Manufacturing Acousto-Optic Light Engine (SLAM – ALE)
Transient Liquid Phase Surface Smoothing
Tribo-Mechanical and Corrosion Characteristics of SS316L-IN625 Alloys of Varying Compositions Fabricated by Twin Wire WAAM-TIG
Two-Component Thermoset Polymer Formwork for Concrete Casting
Uncovering Process-Structure Relationships in Directed Energy Deposition of Nickel-Based Alloys on Low-Alloy Steel with Post-Deposition Heat Treatment
Understanding Hardening Behavior Induced by Interlayer Shot Peening in Laser Powder Bed Fusion of 316L Stainless Steel
Understanding Multi-Line Printing and the Effects of Controlled Prewetting on Binder Jetting Print Cohesion
Understanding the Effect of Retained Austenite on Mechanical Properties of Additive Manufactured 1.2709 Grade Maraging Steel
Understanding the Feasibility of Using NiTi55 Interlayer for Ti6Al4V-18Ni Maraging Steel Multi-Metal Deposition in L-PBF
Use of In-Situ Thermography to Study Scan Strategy for Laser Foil Printing of Metallic Glass
Using Acoustic Signals For Torch-to-Bead Distance Estimation and Closed-Loop Control in Wire Arc Additive Manufacturing
Using Coaxial Melt Pool Images to Construct In-Process 3D Volume Model in Powder Bed Fusion Additive Manufacturing
Using Machine Learning-Based Process Map to Guide Evaluation of Inconel 625 Mechanical Properties in Laser Foil Printing
Vat Photopolymerization of Ultra-Soft Polymer Foams
Vision-Based Calibration of Robotic 3D Printers for Cooperative 3D Printing
Volumetric Medical Models: Direct Imaging to Functional 3D Prints
Wire Arc Additive Manufacturing Benefits and Challenges: A Survey
Wire Arc Additive Manufacturing Development for Aluminum 6061 RAM
Wire Arc Additive Manufacturing of a Large Scale, High Aspect Ratio, Multi-Material Part
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