@inproceedings{657066de51da4d98b641dd608b9fd628,
title = "Flaw Detection in Wire Arc Additive Manufacturing Using In-Situ Acoustic Sensing and Graph Signal Analysis",
abstract = "The goal of this work is to detect flaw formation in wire arc additive manufacturing (WAAM). This process uses an electric arc as the energy source in order to melt metallic wire and deposit the new material, similar to metal inert gas (MIG) welding. Industry has been slow to adopt WAAM due to the lack of process consistency and reliability. The WAAM process is susceptible to a multitude of stochastic disturbances that cause instability in the electric arc. These arc instabilities eventually lead to flaw formation such as porosity, spatter, and excessive deviations in the desired geometry. Therefore, the objective of this work is to detect flaw formation using in-situ acoustic (sound) data from a microphone installed near the electric arc. This data was processed using a novel wavelet integrated graph theory approach. This approach detected the onset of multiple types of flaw formations with a false alarm rate of less than 2%. Using this method, this work demonstrates the potential for in-situ monitoring and flaw detection of the WAAM process in a computationally tractable manner.",
keywords = "Automation, Control, Rapid Prototyping and Solid Freeform Fabrication, Welding and Joining",
author = "Benjamin Bevans and Andr{\'e} Ramalho and Ziyad Smoqi and Aniruddha Gaikwad and Santos, {Telmo G.} and Prahalada Rao and Oliveira, {J. P.}",
note = "Funding Information: info:eu-repo/grantAgreement/FCT/OE/UI%2FBD%2F151018%2F2021/PT# Andr{\'e} Ramalho, Telmo G. Santos and J.P. Oliveira acknowledge Funda{\c c}{\~a}o para a Ci{\^e}ncia e a Tecnologia (FCT-MCTES) for its financial support via the project UID/00667/2020 (UNIDEMI). JPO acknowledges the funding of CENIMAT/i3N by national funds through the FCT-Funda{\c c}{\~a}o para a Ci{\^e}ncia e a Tecnologia, I.P., within the scope of Multiannual Financing of R&D Units, reference UIDB/50025/2020-2023. This activity has received funding from the European Institute of Innovation and Technology (EIT) – Project Smart WAAM: Microstructural Engineering and Integrated Non-Destructive Testing. Prahalada Rao acknowledges funding from the Department of Energy (DOE), Office of Science, under Grant number DESC0021136, and the National Science Foundation (NSF) [Grant numbers CMMI-1719388, CMMI-1920245, CMMI-1739696, CMMI-1752069, PFI-TT 2044710, ECCS 2020246] for funding his research program. This work espousing the concept of online process monitoring in WAAM was funded through the foregoing DOE Grant (Program Officer: Timothy Fitzsimmons), which supported the doctoral graduate work of Mr. Benjamin Bevans. The XCT work was performed at the Nebraska Nanoscale Facility: National Nanotechnology Coordinated Infrastructure under award no. ECCS: 2025298, and with support from the Nebraska Research Initiative through the Nebraska Center for Materials and Nanoscience and the Nanoengineering Research Core Facility at the University of Nebraska-Lincoln. Publisher Copyright: Copyright {\textcopyright} 2023 by ASME.; ASME 2023 18th International Manufacturing Science and Engineering Conference, MSEC 2023 ; Conference date: 12-06-2023 Through 16-06-2023",
year = "2023",
month = sep,
day = "28",
doi = "10.1115/msec2023-101622",
language = "English",
series = "International Manufacturing Science and Engineering Conference",
publisher = "ASME - The American Society of Mechanical Engineers",
booktitle = "Additive Manufacturing; Advanced Materials Manufacturing; Biomanufacturing; Life Cycle Engineering",
address = "United States",
}
