Design of multi-arc collaborative additive manufacturing system and forming performance research

Abstract

In view of the key issue of high-quality wire-arc-additive-manufacturing (WAAM) of large metal components, this paper has devised a suite of multi-arc collaborative additive manufacturing equipment endowed with functionalities for controlling arc behavior, managing melt pool dimensions, conducting 3D measurements, and executing subtractive machining. In the initial phase, a cutting-edge five-arc additive manufacturing head apparatus was meticulously engineered. This apparatus ingeniously blends two single-wire torches augmented by three-wire oscillating torches, synergizing deposition metal performance and forming effective. Subsequently, extensive research was carried out to explore a master-slave control-based method for orchestrating the synchronized movements of multiple robotic entities. This diligent investigation culminated in the seamless integration of a multi-arc collaborative additive manufacturing equipment, comprising five-arc high-efficiency additive units, a 3D measurement module, and a precision-driven subtractive machining unit. The influence of different horizontal distances between arc guns on the temperature field and mechanical properties of components was investigated through process experiments. The research results indicate that as the horizontal spacing between the arc guns increases, the cooling rate of the deposited metal gradually slows down, leading to an extended period of elevated temperatures. As a result, both tensile strength and yield strength gradually decrease, while elongation and impact absorption capacity first increase and then decrease. In the end, the developed equipment was utilized to fabricate large ship propeller bracket components, achieving a remarkable 4.7 times increase in manufacturing efficiency compared to single-arc additive manufacturing.