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A review on wire-arc additive manufacturing: typical defects, detection approaches, and multisensor data fusion-based model

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Abstract

Wire-arc additive manufacturing (WAAM) technology integrates the characteristics of additive manufacturing and traditional welding technology. It has been found to be capable of forming large-scale metal components with low cost and higher deposition rates. However, it also has potential issues in morphological accuracy, microstructure, and properties due to the arc-based metallurgy mechanisms with complex thermal cycles. This article intends to give a detailed overview of the quality diagnosis and control of the WAAM process, including the formation mechanisms of typical defects, detection approaches, and detection challenges that remain in the WAAM industrial environments. Subsequently, a multisensor data fusion-based closed-loop quality control model is proposed. This model could provide a feasible solution to ensure the quality and deposition efficiency of WAAM parts in complex manufacturing conditions. Based on this model, a novel process named hybrid deposition and micro-rolling (HDMR) is introduced as the green transformation of traditional manufacturing approaches with higher energy efficiency and better quality.

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Funding

This work is supported by the China Scholarship Council.

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Authors and Affiliations

  1. School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan, 430074, Hubei, China

    Xi Chen, Youheng Fu, Runsheng Li & Haiou Zhang

  2. Research Center for Advanced Manufacturing, Southern Methodist University, 3101 Dyer Street, Dallas, Texas, 75205, USA

    Xi Chen

  3. ESAB Advanced Joining Center at SMU, Dallas, Texas, 75205, USA

    Fanrong Kong

  4. School of Aerospace Engineering, Huazhong University of Science and Technology, Wuhan, 430074, Hubei, China

    Xushan Zhao & Guilan Wang

  5. School of Materials Science and Engineering, Huazhong University of Science and Technology, Wuhan, 430074, Hubei, China

    Guilan Wang

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  1. Xi Chen
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  3. Youheng Fu
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  7. Haiou Zhang
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Contributions

Xi Chen and Fanrong Kong analyzed and summarized the work of relevant literatures, and wrote the manuscript. Youheng Fu, Xushan Zhao, and Runsheng Li provided some material for the manuscript and the drawing of the picture. Guilan Wang and Haiou Zhang reviewed the manuscript.

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Correspondence to Haiou Zhang.

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Chen, X., Kong, F., Fu, Y. et al. A review on wire-arc additive manufacturing: typical defects, detection approaches, and multisensor data fusion-based model. Int J Adv Manuf Technol 117, 707–727 (2021). https://doi.org/10.1007/s00170-021-07807-8

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