Strategies for dimensional accuracy and precision in additive manufacturing of large components through first-time-right approaches and residual stress control

Additive manufacturing of large steel components such as ship gearbox housings using laser-assisted wire arc welding has the potential to save material, energy and costs compared to conventional manufacturing methods. The process was identified as energy- and resource-efficient in the finished project "XXL3DDruck". However, due to the occurrence of residual stresses and component distortion, it cannot yet be used economically in an industrial manufacturing environment. The aim of this joint project is therefore to optimize the manufacturing process with regard to these limitations and to qualify it for industrial use.

To achieve this, six subprojects address various aspects of distortion and residual stress formation. The IPH is leading the subproject "Digitalization and Artificial Intelligence in Additive Manufacturing." This subproject involves research into an automated inline control process based on external data processing. Process and sensor data are to be processed with the aid of artificial intelligence (AI) to ensure compliance with specified printing tolerances through CAD manipulation and parameter control. All collected data will be integrated in a digital twin.