Towards Efficient Monitoring for WAAM Processes on a Robotized and Reconfigurable Manufacturing Cell

Abstract

Wire Arc Additive Manufacturing (WAAM) is an efficient technology for producing metal parts. It offers high deposition rates, low material waste and reduced machining costs. However, the process's complex multi-physics nature presents several challenges, particularly with regard to residual stresses, deposition accuracy, and internal defects. Internal defects that occur during the WAAM process are difficult to detect in real time or immediately after fabrication without the use of non destructive testing methods.This study focuses on enhancing an experimental protocol that employs a monitoring method analysing the geometry of each deposited layer using a laser sensor. This approach, combined with segmentation techniques, aims to identify and locate internal defects. Specifically, the proposed method relies on segmenting individual layers and comparing normalised values to detect and localise defects. This paper presents the developed methodology and an initial validation of its effectiveness.