Abstract
Abstract
Wire Arc Additive Manufacturing (WAAM), also referred to as DED-Arc in ISO/ASTM 52900:2021, is gaining significant attention in the aerospace industry for its ability to fabricate large-scale structures by integrating a welding torch as an end effector onto a 6-axis industrial robot. However, challenges persist regarding the consistency of deposition quality primarily due to thermal deformation from high heat input, and constraints in geometric complexity. In this study, we developed a hybrid manufacturing system that integrates WAAM with a milling process. In-process deposition height feedback control is also implemented through the synchronized operation of a WAAM robot and a multi-task robot equipped with a laser profiler. To verify the feasibility of the proposed system, a propellant tank (1 m major diameter, 0.5 m minor diameter, 5 mm wall thickness, 1.1 m height) was fabricated using aluminum alloy AA5183. Hydrostatic testing indicated yield pressures of 1.30 MPa in the cylindrical section and 1.38 MPa in the lower dome, which aligned well with theoretical calculations based on the tensile strength of the WAAM-deposited material. Finally, FEM-based simulations were compared with experimental data.