Connected, digitalized wire arc additive manufacturing: utilizing data in the internet of production to enable industrie 4.0

Abstract

Abstract This work explores the potential of connected, digitalized Wire Arc Additive Manufacturing (WAAM) within the framework of Industrie 4.0, analyzing it through distinct process layers: workpiece, assembly, and product. Each layer presents unique timeframes and stakeholder interactions, necessitating varied data infrastructure demands, including a consideration of data security and privacy challenges. The workpiece layer mostly covers the local production setup and is thus directly coupled with the product and process quality as well as maintaining a safe operation. In the assembly layer, ensuring interoperability among diverse stakeholders is crucial, requiring clear definitions of responsibilities and access rights to enhance data exchange. The product layer prioritizes the reliability and trustworthiness of information for informed decision-making, advocating for solutions that guarantee authenticity and verifiability while addressing privacy concerns through techniques like privacy-preserving computing. The paper identifies a critical gap in real-world applications of these concepts in additive manufacturing. It proposes a data-driven quality control approach to enhance process and product quality in arc welding, leveraging digital shadows to create effective interfaces within production networks. This approach has demonstrated potential reductions in welding fume emissions by 12–40%, alongside connected applications that minimize exposure and energy consumption.