Possibility of Applying 3DLD Technology for Real-Time Control of Multi-Layer Wire Arc Additive Manufacturing

Abstract

This paper introduces a novel Geometric Process Control Paradigm (3DLD GPC) for Wire Arc Additive Manufacturing (WAAM) and automated surface restoration of large-scale components. According to this concept, the macro-geometric quality of the deposited layer is governed by the spatial-coordinate optimization of robotic trajectories rather than the excessive complication of the power source pulsed waveforms. The fundamental Laplace equation forms the mathematical engine, computing the theoretical reference profiles of the deposited weld beads for any spatial orientation. By integrating these physical references with the Pankov-Chernyshov multi-pass path-planning algorithm, it is demonstrated that the optimization of welding parameters during bead placement suppresses the maximum layer waviness by 65.3% to 80.9% compared to conventional empirical trajectories. This method flattens the layer topography, accurately driving the deposited geometry toward the nominal CAD model. The proposed framework provides an efficient geometric pathway to minimize macro-defects and porosity, thereby lowering the requirements for subsequent Hot Isostatic Pressing (HIP) and significantly reducing the machining allowances for finish CNC milling.