Efficient bead-on-plate weld model for parameter estimation towards effective wire arc additive manufacturing simulation

• Published in: Welding in the world Vol. 68; no. 4; pp. 969 - 986
• Main Authors: Strobl, Dominic, Unger, Jörg F., Ghnatios, Chady, Klawonn, Alexander, Pittner, Andreas, Rethmeier, Michael, Robens-Radermacher, Annika
• Format: Journal Article
• Language: English
• Published: Berlin/Heidelberg Springer Berlin Heidelberg 01.04.2024; Springer Nature B.V
• Subjects: Additive manufacturing; Bead on plate welding; Chemistry and Materials Science; Finite element method; Manufacturing; Materials Science; Mathematical models; Metallic Materials; Model reduction; Numerical methods; Parameter estimation; Process controls; Real time; Reduced order models; Research Paper; Simulation; Solid Mechanics; Theoretical and Applied Mechanics; Welding parameters; Hardly separable problem; Proper generalized decomposition; Model order reduction; Model calibration; Additive manufacturing; Wire arc additive manufacturing
• ISSN: 0043-2288; 1878-6669
• DOI: 10.1007/s40194-024-01700-0

Despite the advances in hardware and software techniques, standard numerical methods fail in providing real-time simulations, especially for complex processes such as additive manufacturing applications. A real-time simulation enables process control through the combination of process monitoring and automated feedback, which increases the flexibility and quality of a process. Typically, before producing a whole additive manufacturing structure, a simplified experiment in the form of a bead-on-plate experiment is performed to get a first insight into the process and to set parameters suitably. In this work, a reduced order model for the transient thermal problem of the bead-on-plate weld simulation is developed, allowing an efficient model calibration and control of the process. The proposed approach applies the proper generalized decomposition (PGD) method, a popular model order reduction technique, to decrease the computational effort of each model evaluation required multiple times in parameter estimation, control, and optimization. The welding torch is modeled by a moving heat source, which leads to difficulties separating space and time, a key ingredient in PGD simulations. A novel approach for separating space and time is applied and extended to 3D problems allowing the derivation of an efficient separated representation of the temperature. The results are verified against a standard finite element model showing excellent agreement. The reduced order model is also leveraged in a Bayesian model parameter estimation setup, speeding up calibrations and ultimately leading to an optimized real-time simulation approach for welding experiment using synthetic as well as real measurement data.