Research challenges, quality control and monitoring strategy for Wire Arc Additive Manufacturing

Abstract

Metal additive manufacturing is a high-growth process owing to the capability of producing parts with complicated geometries and custom facets for various applications. The low material input ratio to final part output, in which minimum raw materials are needed to produce complex parts and thin-walled components with a large volume envelop-to-volume ratio, is advantageous compared to the conventional method. The Wire Arc Additive Manufacturing (WAAM) method has undergone significant research and advancement because it can be utilised to produce large metal components at high deposition rates as well as low cost and with better mechanical and microstructural properties than other AM techniques. Because of the significant amounts of processing temperature, various issues and defects arise during the process, hampering high-quality component manufacturing in WAAM. In addition, these components often have an insufficient and poor surface, affecting the metal components' quality. This article reviews common defects and research challenges associated with manufacturing different metal and alloy components using the WAAM process. Various control strategies in WAAM methods, which are essential to reduce or minimise defects to form high-quality metal parts, are summarised. Recent research on implementing artificial intelligence (AI) in quality improvement is discussed. The strategy for quality control using the multi-sensor-based closed-loop system is proposed in conclusion. This strategy could serve as a roadmap for ensuring the deposit efficiency and quality of WAAM components under complex, high-volume manufacturing circumstances.