Double electrode micro plasma arc additive manufacturing control system based on adaptive height adjustment

Double electrode micro plasma arc welding was used to carry out the experiments for depositing the weld beads with the maximum deposition rate in xPC Target real-time environment, and the relationships between the process parameters such as the wire feed rate, the torch stand-off distance and the total voltage were investigated. With data analysis, the regression models of the wire feed rate and the total voltage were developed. Furthermore, a self-adaptive height adjustment control model combining the variable wire feed rate and voltage feedback in xPC Target system was created. Consequently, the double electrode micro plasma arc welding additive manufacturing control system based on the self-adaptive height adjustment was developed, and the experiments of depositing on the step shaped substrate and self-adaptive depositing the thin wall parts were carried out. The results show that the control system can improve the stability of the additive manufacturing process; optimize the deposition path design in the height direction; realize depositing the metal parts on the complex shape substrate.