Invention Reference Number
This technology introduces a novel method for maintaining precise standoff distance in Wire Arc Additive Manufacturing (WAAM) systems. By leveraging airborne acoustic emissions, the system enables continuous, real-time monitoring that improves manufacturing accuracy, efficiency, and part quality. The approach addresses longstanding challenges with current measurement techniques that are slow, inaccurate, or prone to equipment wear, ultimately reducing errors and downtime while supporting advanced additive manufacturing applications.
Description
WWAAM requires precise control of the standoff distance—the gap between the deposition nozzle and the surface being built—to ensure part quality and consistency. Traditional measurement methods often suffer from limitations, such as inaccuracies caused by sensor wear, occlusion in complex geometries, or the need for time-intensive post-layer measurements. This invention overcomes these issues by introducing a new way of determining standoff distance based on acoustic emissions captured during the build process. The system integrates an acoustic sensing mechanism with a predictive model that interprets sound patterns associated with the welding process. These acoustic signals are continuously analyzed to estimate standoff distance, providing a non-intrusive, efficient, and reliable alternative to conventional methods. By offering improved real-time monitoring without slowing the build or relying on delicate equipment, this technology enhances quality control and reduces the variability that often challenges WAAM adoption in industrial applications.
Benefits
- Real-time monitoring of standoff distance
- Non-intrusive measurement approach
- Improved accuracy and part quality
- Reduced downtime and equipment wear
Applications and Industries
- Additive manufacturing process optimization
- Aerospace and automotive manufacturing
- Heavy industry and energy sector fabrication
- Robotics-assisted advanced manufacturing
Contact
To learn more about this technology, email partnerships@ornl.gov or call 865-574-1051.
