About this Abstract |
Meeting |
2025 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2025)
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Symposium
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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 |