Wire arc additive manufacturing (WAAM) is well suited for the manufacture of sizeable metallic workpieces featuring medium-to-high geometrical complexity due to its high deposition rate, low processing conditions limit, and environmental friendliness. To enhance the current capability of the WAAM process for fabricating structures with complex geometry, this paper proposes a robot-based WAAM strategy adapted specifically for fabricating freeform parts with wire structures composed of multiple struts. Contributions in this work include: (i) The study of bead modelling, which establishes optimal welding parameter selection for the process; (ii) the novel manufacturing strategy, including the adaptive slicing methodology and height control system for accurately depositing every single strut; and (iii) detailed manufacturing procedures for multi-strut branch intersections as well as the collision-free path planning to control the overall fabrication process. To verify the effectiveness of this proposed WAAM approach, two complex wire structures were fabricated successfully, indicating the feasibility of the proposed fabrication strategy.

电弧增材制造 (WAAM) 具有高沉积率、低加工条件限制和环境友好性，非常适合制造具有中高几何复杂性的大型金属工件。为了提高 WAAM 工艺在制造具有复杂几何形状的结构方面的当前能力，本文提出了一种基于机器人的 WAAM 策略，该策略专门适用于制造具有由多个支柱组成的线结构的自由形状零件。这项工作的贡献包括： (i) 焊道建模的研究，为工艺建立最佳焊接参数选择；(ii) 新颖的制造策略，包括用于准确放置每个支柱的自适应切片方法和高度控制系统；(iii) 多支柱分支交叉点的详细制造程序以及控制整个制造过程的无碰撞路径规划。为了验证所提出的 WAAM 方法的有效性，成功制造了两种复杂的线结构，表明所提出的制造策略的可行性。