丝材定向能量沉积增材制造在线监测与过程控制综述

A review of online monitoring and process control for wire-based directed energy deposition additive manufacturing

丝材定向能量沉积(W-DED)是以丝材为原材料的一种增材制造技术,具有高效率、高精度、高材料利用率的特点。然而,在丝材熔化与沉积过程中,可能因过度热输入而导致沉积缺陷的形成。因此,需要使用在线监测技术对沉积过程中的熔池和沉积层等对象进行监测,从而实现对沉积工艺参数的控制优化。多模态信号融合方法能够利用来自不同模态的物理信息来提升监测任务的准确性和稳定性。首先,总结了丝材定向能量沉积技术在线监测对象与成形质量的关系;然后,对现有在线监测技术进行分类,并对其相关沉积参数的过程控制方法进行整理;最后,总结了当前丝材定向能量沉积增材制造在线监测与过程控制方面的研究进展和挑战,并展望了未来的研究方向。

Wire-based Directed Energy Deposition(W-DED)is an additive manufacturing technology that uses wire as the feedstock,characterized by its high efficiency,precision,and utilization rate.However,the process of melting and depositing the wire material may lead to the formation of deposition defects due to excessive heat input.Consequently,it is necessary to employ online monitoring techniques to observe the molten pool and deposited layers during the deposition process,thereby optimizing the control of the deposition process parameters.Multimodal signal fusion methods can enhance the accuracy and stability of monitoring tasks by utilizing physical information from different modalities.This paper first summarizes the relationship between the online monitoring targets of W-DED technology and the quality of the formed parts.It then categorizes the existing online monitoring techniques and compiles their related process control methods for deposition parameters.Lastly,the paper reviews the current research progress and challenges in W-DED concerning online monitoring and process control,and proposes future research directions.