Design of Additive Manufacturing Processes: AI Based Real-Time Power Prediction Models

Additive Manufacturing (AM) processes are widely used to create complex three-dimensional products by depositing material layer by layer. This approach contrasts significantly with subtractive manufacturing processes, where material is removed to shape the final product. In wire-arc directed energy deposition (wa-DED), a generative scheme is employed to build parts from the base up using power supplied by a welding arc. When optimizing wa-DED processes, it is crucial to predict welding power, deposition speed, and thermal history to enable accurate modeling of the process. These parameters are typically predicted based on material properties, part geometry, deposition method, and the limitations of the printing machine.