Modelling the Weld Cladding Process to Predict Weld Clad Position and Shape Error

Abstract

Abstract Wire Arc Additive Manufacturing (WAAM) is one of the most productive metal additive manufacturing methods. One of its most promising applications holds in manufacturing of difficult-to-cut materials where production costs can be reduced with minimizing the time of machining and total tool costs. To develop a correct WAAM technological process for manufacturing complex shaped components welding torch path corrections and welding power corrections have to be made especially in critical sections such as corners and sharp edges. A predictive mathematical model of the material cladding during WAAM process has been developed for the purposes of generating an optimal toolpath of the WAAM clads. This predictive mathematical model is simplified to reflect the important physical phenomena in the weld pool but also to optimize computing time. In this paper the principle of the mathematical model is described and its functionality is verified by the welding experiments with five different welding power settings. 3D scans of welded samples are used for the verification.