Development of a novel TIG hot-wire process for wire and arc additive manufacturing

The presented work deals with the development of a novel TIG hot-wire process for the additive manufacturing of metallic components, which, in contrast to previous arc processes, enables a significant increase in melting performance with simultaneously reduced heat input. This is achieved by means of an upstream resistance heating of the wire between two contact points within the hot wire feeding system. The torch, hot wire feeder and gas nozzle are designed in such a way that a constant bead geometry can be guaranteed regardless of the machining direction. On the one hand, this can improve the dimensional accuracy; on the other hand, an increase in productivity is achieved through a significant reduction of process times. Essential parts of the work include the simulation-supported development of the processing system, the design and implementation of an innovative process control system and the testing of the new technology.