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  4. Investigating the Impact of Process Parameters on Bead Geometry in Laser Wire-Feed Metal Additive Manufacturing
 
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September 19, 2024
Journal Article
Title

Investigating the Impact of Process Parameters on Bead Geometry in Laser Wire-Feed Metal Additive Manufacturing

Abstract
Laser wire-feed metal additive manufacturing (LWAM) is an innovative technology that shows many advantages compared with traditional manufacturing approaches. Despite these advantages, its industrial adoption is limited by complex parameter management and inconsistent process quality. To address these issues and improve geometric accuracy, this study explores how process parameters influence bead geometry. We conducted a parameter study varying laser power, wire feed rate, traverse speed, and welding angle. Using a full factorial design with a central composite design methodology, we assessed bead height and width. This allowed us to develop a model to estimate ideal process parameters. The findings offer a detailed analysis of parameter interactions and their effects on bead geometry, aiming to enhance geometric accuracy and process stability in LWAM. Moreover, we have evaluated the proposed process parameters from our developed model, which showed a significant enhancement to the overall quality. This was validated via printing a single layer and multi-layer structures. The quality of the final predicted sample using the proposed method was improved by 40% compared to the best sample produced for the Design of Experiment trials.
Author(s)
Abuabiah, Mohammed
An-Najah National University
Weidemann, Tizia Charlotte
Fraunhofer-Institut für Produktionstechnologie IPT  
Elahi, Mahdi Amne
University of Luxembourg
Shaqour, Bahaa
An-Najah National University
Day, Robin  
Fraunhofer-Institut für Produktionstechnologie IPT  
Plapper, Peter
University of Luxembourg
Bergs, Thomas  
Manufacturing Technology Institute – MTI
Journal
Journal of manufacturing and materials processing  
Project(s)
Boosting the surface quality and geometric accuracy in laser additive manufacturing via a novel data-driven control system design  
Funder
European Commission  
Open Access
DOI
10.24406/publica-3715
10.3390/jmmp8050204
File(s)
Full text.pdf (5.59 MB)
Rights
CC BY 4.0: Creative Commons Attribution
Language
English
Fraunhofer-Institut für Produktionstechnologie IPT  
Keyword(s)
  • Laser wire-feed metal additive manufacturing

  • Bead geometry

  • Design of experiment

  • Process optimization

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