Advancing Wire Arc Additive Manufacturing: A New Era of Precision and Efficiency in Large Metal Component Production

A comprehensive Wire Arc Additive Manufacturing (WAAM) approach that employs five algorithms to improve massive metal components is described in this research. The adaptive layer thickness control algorithm adjusts layer thickness based on real-time complexity. This ensures additive manufacturing accuracy throughout. Also, the Material Versatility Optimization Algorithm simplifies working with multiple materials, making casting more efficient. The Intelligent Path Planning Algorithm allocates the robotic arm’s movement to traverse the shortest distance and uniformly distribute heat during deposition. The MultiMaterial-Materialon Strategy Algorithm improves material amounts, making WAAM more usable for additional materials. The Real-Time Excellent Assurance Algorithm constantly examines and adjusts parameters to ensure excellent production. A complete analysis of research reveals how algorithms are related and how vital they are for accuracy, speed, and flexibility. Testing shows that the recommended technique controls layer thickness, material variety, deposition velocity, accuracy, energy efficiency, and real-time tracking better than typical WAAM methods. Figures 6, 7, and 8 indicate that the proposed method delivers superior results across several criteria. The recommended WAAM approach can create more massive metal components by fundamentally changing how things are done. This research provides a comprehensive additive manufacturing approach to solve numerous large-scale metal production issues.