Advanced multi-sensor monitoring system in wire arc additive manufacturing for enhanced process and parts production
Alessia Teresa Silvestri, Andrea El Hassanin, Giorgio de Alteriis, Eleonora Viola, Rosario Schiano Lo Moriello, Antonino Squillace
Abstract. Wire Arc Additive Manufacturing (WAAM) is a Directed Energy Deposition (DED) technology widely recognized for its capability to produce large-scale components, repair damaged parts, and achieve high deposition rates. Among WAAM processes, the Cold Metal Transfer (CMT) technique has garnered significant attention due to its low heat input and stable short-circuiting behavior, resulting in reduced spatter and enhanced control. This study aims to develop robust monitoring strategies to evaluate process quality and detect potential anomalies during the WAAM-CMT process. Single tracks of ER70S-6 steel were deposited, and a comprehensive monitoring system was implemented, incorporating two types of MEMS accelerometers and a digital microphone to capture acceleration, vibration, and acoustic emissions during the printing process. The proposed approach demonstrated its effectiveness in identifying potential defects and anomalies, contributing to the early detection of process instabilities. The findings provide a reliable framework for real-time monitoring and quality assurance in WAAM applications, highlighting the potential of sensor-based methodologies to enhance manufacturing outcomes.
Keywords
WAAM, Cold Metal Transfer, Monitoring
Published online 5/7/2025, 10 pages
Copyright © 2025 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA
Citation: Alessia Teresa Silvestri, Andrea El Hassanin, Giorgio de Alteriis, Eleonora Viola, Rosario Schiano Lo Moriello, Antonino Squillace, Advanced multi-sensor monitoring system in wire arc additive manufacturing for enhanced process and parts production, Materials Research Proceedings, Vol. 54, pp 264-273, 2025
DOI: https://doi.org/10.21741/9781644903599-29
The article was published as article 29 of the book Material Forming
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
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