Arc length monitoring and closed-loop quality control for GTA-WAAM

This study aims to enhance the monitoring and control of arc length in Wire Arc Additive Manufacturing with Gas Tungsten Arc (GTA-WAAM). Accurate measurement and closed-loop control of arc length in WAAM is challenging, especially under conditions of low image quality or high-intensity lighting. To address these challenges, we propose the arc length monitoring methodology by combining automatic image segmentation, robust target tracking, and accurate abnormal image identification. A feedback control method is also developed based on adaptive fuzzy logic for manufacturing quality control. Based on arc length measurement, the process parameter is attuned to stabilize the arc length, in order to control manufacturing quality. Our quality control experiments on rod manufacturing demonstrated the effectiveness of the proposed arc length measurement and feedback control methods. The monitoring and feedback control methods developed in this study can help facilitate the development of the next generation metal additive manufacturing technology with high precision and control.