The production method of Wire-Arc Additive Manufacturing (WAAM) belongs to the class of additive manufacturing processes that are increasingly being used in industry for the material-efficient production of weight-efficient workpieces. In WAAM, a wire is melted by a welding head and applied in layers to a base plate. The temperature differences occurring within the workpiece during production and the selected path of the welding head have a significant influence on the quality of the finished component. It is therefore desirable to select a path that not only produces the most even temperature distribution possible in the workpiece, but also differs as much as possible from the path of the previous layer. This helps to reduce stresses in the material and increase the stability of the component.

In order to find an optimal construction plan for a given component, we formulate the problem as a discrete-continuous linear optimisation problem. We discretise the heat conduction equation and linearise the occurring radiation terms in order to calculate optimal paths for the individual planes with the help of mixed-integer linear solvers.

Partner

Prof. Markus Bambach, Chair of Construction and Manufacturing
Prof. Michael Breuß, Chair of Applied Mathematics

Lectures

• Temperature Based Trajectory Optimisation for Wire-Arc Additive Manufacturing, 8th TOR Workshop, Siegen, 09.03.2021.
• Temperature Based Trajectory Optimisation for Wire-Arc Additive Manufacturing, SIGOPT 2020, Dortmund, 04.03.2020.
• Temperature Based Trajectory Optimisation for Wire-Arc Additive Manufacturing, WSOPT 2019, Olbernhau, 14.03.2019.

Publications of

• Martin Bähr, Johannes Buhl, Georg Radow, Johannes Schmidt, Markus Bambach, Michael Breuß, Armin Fügenschuh, Stable honeycomb structures and temperature based trajectory optimization for wire-arc additive manufacturing, Optimisation and Engineering, Vol. 22, Issue 2, pp. 913-974, 2021.
• Armin Fügenschuh, Markus Bambach, Johannes Buhl, Trajectory optimisation for wire-arc additive manufacturing, Operations Research Proceedings 2018. Springer, Cham, pp. 331-337, 2019.