Robotic Wire + Arc Additive Manufacture cell
Lead Research Organisation:
University of Strathclyde
Department Name: Electronic and Electrical Engineering
Abstract
Additive manufacturing (AM) has gained significant interests from industries of different sectors. Among different AM processes, Wire + Arc Additive Manufacturing (WAAM), which used metal wire as feedstock and electric arc as a heat source, has been shown to be suitable for producing large scale components with comparatively low equipment cost and running cost. The WAAM process has been developed in Cranfield University for many years, many large components of different materials, including titanium alloys, aluminium alloys, nickel alloys as well as steels have been successfully built for industrial partners.
The end-user industries, such as Airbus, FMC technologies and Glemalmond Group see significant benefits presented by the WAAM process to be able to manufacture structural components in a short lead time with low cost. Kuka Systems sees the great opportunity to get the forefront of this technology and to get the business benefit from commercialisation of the first WAAM machine. The main target of this project is to develop a commercial robotic WAAM machine (ROBOWAAM) that can be used by industrial partners for building meter scale components. Cranfield University will integrate its extensive WAAM process knowledge into a feature- based path planning software to support the end-users to manufacture components for their applications. In additional an online feedback control system will be developed and integrated into ROBOWAAM machine to correct build height errors.
To assure the deposition quality of the part, in-process nondestructive testing (NDT) method needs to be applied. Usually NDT is applied after the components has been finished. It is a time consuming and costly process if a defect is found which would either require a repair procedure or may lead to scrapping of the part. Thus an in-process NDT method is required to for inspecting each layer of the deposition. If a defect is found then the current layer will need to be machined before the recommence of the deposition. Cranfield University will collaborate with the University of Strathclyde and Advanced Forming Research Centre (AFRC) on a feasibility study of the in-process NDT method on the WAAM parts with existing NDT technologies. The in-process NDT will be incorporated with the WAAM process into a parallel processing system and the capability of this system will be demonstrated in this project.
In addition, an extended study will be performed on the automation requirements of the whole WAAM chain. This will include the pre-WAAM processes such as substrate cleaning, post-WAAM process such as heat treatment and final machining, parallel processes such as in-process NDT and top surface machining, as well as material manipulation between processes.
The end-user industries, such as Airbus, FMC technologies and Glemalmond Group see significant benefits presented by the WAAM process to be able to manufacture structural components in a short lead time with low cost. Kuka Systems sees the great opportunity to get the forefront of this technology and to get the business benefit from commercialisation of the first WAAM machine. The main target of this project is to develop a commercial robotic WAAM machine (ROBOWAAM) that can be used by industrial partners for building meter scale components. Cranfield University will integrate its extensive WAAM process knowledge into a feature- based path planning software to support the end-users to manufacture components for their applications. In additional an online feedback control system will be developed and integrated into ROBOWAAM machine to correct build height errors.
To assure the deposition quality of the part, in-process nondestructive testing (NDT) method needs to be applied. Usually NDT is applied after the components has been finished. It is a time consuming and costly process if a defect is found which would either require a repair procedure or may lead to scrapping of the part. Thus an in-process NDT method is required to for inspecting each layer of the deposition. If a defect is found then the current layer will need to be machined before the recommence of the deposition. Cranfield University will collaborate with the University of Strathclyde and Advanced Forming Research Centre (AFRC) on a feasibility study of the in-process NDT method on the WAAM parts with existing NDT technologies. The in-process NDT will be incorporated with the WAAM process into a parallel processing system and the capability of this system will be demonstrated in this project.
In addition, an extended study will be performed on the automation requirements of the whole WAAM chain. This will include the pre-WAAM processes such as substrate cleaning, post-WAAM process such as heat treatment and final machining, parallel processes such as in-process NDT and top surface machining, as well as material manipulation between processes.
Planned Impact
A number of fundamental knowledge exchange activities will occur during the course of this project. The academic partners will benefit greatly from the cross fertilisation of knowledge between the two established centres - Cranfield representing the advanced welding technologies, and Strathclyde representing the Non-Destructive Testing capabilities. Of course this knowledge will feed directly into the end user and supply chain partners as well as our other professional networks.
Specific impacts to be driven by this research include:
Helping to disseminate new NDT integration knowledge to KUKA Systems. Integration of NDT technologies into future systems will help diversify KUKA Systems product portfolio thus contributing to new jobs and UK economy.
Integrating new in-process NDT measurements into additive manufacturing will improve the quality and performance of finished parts supplied by the end users (Airbus Defence and Space, FMC Technologies, Glenalmond Group).
Wider industry engagement through dissemination activities to the wider industry base of UK Research Centre in Non-Destructive Evaluation (RCNDE) - nuclear and energy sectors in particular.
Wider academic engagement through network of researchers engaged in EPSRC funded AIMaReM programme (University of Sheffield, AMRC, Los Alamos National Laboratories, RWTH Aachen Germany and University West Sweden). The additive process is well suited to support the workpackages involved in remanufacture in this research.
Supporting UK economy through driving internationally excellent research and development.
Staff and student development will be supported by significant upskilling of staff in cutting edge AM techniques developed through Cranfield. Project students will directly benefit from exposure to latest developments in AM engineering.
Supporting AFRC business plan, through wider engagement with local industry with requirements for advanced robotics, manufacture and repair technologies, and non-destructive testing.
Public engagement activities to include using portable ERIC robotic cell to support public exhibitions, demonstrations and school visits to encourage STEM activities.
Specific impacts to be driven by this research include:
Helping to disseminate new NDT integration knowledge to KUKA Systems. Integration of NDT technologies into future systems will help diversify KUKA Systems product portfolio thus contributing to new jobs and UK economy.
Integrating new in-process NDT measurements into additive manufacturing will improve the quality and performance of finished parts supplied by the end users (Airbus Defence and Space, FMC Technologies, Glenalmond Group).
Wider industry engagement through dissemination activities to the wider industry base of UK Research Centre in Non-Destructive Evaluation (RCNDE) - nuclear and energy sectors in particular.
Wider academic engagement through network of researchers engaged in EPSRC funded AIMaReM programme (University of Sheffield, AMRC, Los Alamos National Laboratories, RWTH Aachen Germany and University West Sweden). The additive process is well suited to support the workpackages involved in remanufacture in this research.
Supporting UK economy through driving internationally excellent research and development.
Staff and student development will be supported by significant upskilling of staff in cutting edge AM techniques developed through Cranfield. Project students will directly benefit from exposure to latest developments in AM engineering.
Supporting AFRC business plan, through wider engagement with local industry with requirements for advanced robotics, manufacture and repair technologies, and non-destructive testing.
Public engagement activities to include using portable ERIC robotic cell to support public exhibitions, demonstrations and school visits to encourage STEM activities.
Publications
Javadi Y
(2021)
High-temperature in-process inspection followed by 96-h robotic inspection of intentionally manufactured hydrogen crack in multi-pass robotic welding
in International Journal of Pressure Vessels and Piping
Javadi Y
(2019)
Ultrasonic phased array inspection of a Wire + Arc Additive Manufactured (WAAM) sample with intentionally embedded defects
in Additive Manufacturing
Javadi Y
(2020)
In-process calibration of a non-destructive testing system used for in-process inspection of multi-pass welding
in Materials & Design
Javadi Y
(2019)
Ultrasonic Phased Array Inspection of Wire + Arc Additive Manufacture Samples Using Conventional and Total Focusing Method Imaging Approaches
in Insight - Non-Destructive Testing and Condition Monitoring
Javadi Y
(2020)
Continuous monitoring of an intentionally-manufactured crack using an automated welding and in-process inspection system
in Materials & Design
Javadi Y
(2021)
Investigating the effect of residual stress on hydrogen cracking in multi-pass robotic welding through process compatible non-destructive testing
in Journal of Manufacturing Processes
Lines D
(2020)
A flexible robotic cell for in-process inspection of multi-pass welds
in Insight - Non-Destructive Testing and Condition Monitoring
Loukas C
(2023)
Transforming Industrial Manipulators via Kinesthetic Guidance for Automated Inspection of Complex Geometries.
in Sensors (Basel, Switzerland)
Loukas C
(2021)
A cost-function driven adaptive welding framework for multi-pass robotic welding
in Journal of Manufacturing Processes
Mohseni E
(2021)
Model-assisted ultrasonic calibration using intentionally embedded defects for in-process weld inspection
in Materials & Design
Mohseni E
(2020)
A Model-Based Study of Transmit-Receive Longitudinal Arrays for Inspection of Subsurface Defects
in Journal of Nondestructive Evaluation, Diagnostics and Prognostics of Engineering Systems
Vasilev M
(2021)
Non-contact in-process ultrasonic screening of thin fusion welded joints
in Journal of Manufacturing Processes
Vasilev M
(2021)
Feed forward control of welding process parameters through on-line ultrasonic thickness measurement
in Journal of Manufacturing Processes
Vithanage R
(2022)
Development of a phased array ultrasound roller probe for inspection of wire + arc additive manufactured components
in Journal of Manufacturing Processes
Vithanage R
(2021)
A Phased Array Ultrasound Roller Probe for Automated in-Process/Interpass Inspection of Multipass Welds
in IEEE Transactions on Industrial Electronics
Zimermann R
(2022)
Collaborative Robotic Wire + Arc Additive Manufacture and Sensor-Enabled In-Process Ultrasonic Non-Destructive Evaluation.
in Sensors (Basel, Switzerland)
Zimermann R
(2021)
Multi-layer ultrasonic imaging of as-built Wire + Arc Additive Manufactured components
in Additive Manufacturing
Zimermann R
(2023)
In-process non-destructive evaluation of metal additive manufactured components at build using ultrasound and eddy-current approaches
in Journal of Manufacturing Processes
Zimermann R
(2022)
Increasing the speed of automated ultrasonic inspection of as-built additive manufacturing components by the adoption of virtual source aperture
in Materials & Design
Description | New NDT techniques for in-process inspection in additive manufacture |
Exploitation Route | In welding technologies - particularly for high integrity, multipass welding |
Sectors | Aerospace Defence and Marine Construction Energy Manufacturing including Industrial Biotechology |
Description | Uptake of technology for commercial WAAM manufacturing |
First Year Of Impact | 2018 |
Sector | Aerospace, Defence and Marine |
Impact Types | Societal Economic |
Description | ABC of ARC |
Amount | £224,000 (GBP) |
Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
Sector | Public |
Country | United Kingdom |
Start | 03/2018 |
End | 03/2020 |
Description | New Wire Additive Manufacturing (NEWAM) |
Amount | £5,886,209 (GBP) |
Funding ID | EP/R027218/1 |
Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
Sector | Public |
Country | United Kingdom |
Start | 05/2018 |
End | 06/2024 |
Description | OAAM - Open Architecture Additive Manufacture |
Amount | £320,619 (GBP) |
Funding ID | 113164 |
Organisation | Innovate UK |
Sector | Public |
Country | United Kingdom |
Start | 09/2017 |
End | 11/2020 |
Description | SEARCH |
Organisation | University of Strathclyde |
Country | United Kingdom |
Sector | Academic/University |
PI Contribution | New technology transfer to industry and academic partners |
Collaborator Contribution | New applications e.g. in pharmaceutical manufacture, welding & joining, cladding |
Impact | New project partnerships with end users - technology demonstrators |
Start Year | 2021 |