Thermal Process Monitoring for Wire-Arc Additive Manufacturing using IR Cameras

Abstract

Wire-arc additive manufacturing systems use robotic MIG welders to build parts using welding wire. As a part is built the temperature rises as energy is input and the thermal mass increases. While some pre-heat is ideal for welding, improper thermal management can lead to defects and negatively affect material properties. Thermal imaging allows for non-contact thermal monitoring and can be used to track thermal gradients as well as layer temperatures before and after deposition providing a method to ensure proper thermal management. A typical IR camera setup on an mBAAM system is discussed along with methods to use thermal monitoring to improve material properties and reduce defects in the final part.