Dual-droplet transition control for improving forming quality and composition homogenizing in dual-wire additive manufacturing of Ti₂AlNb alloy

Dual-wire additive manufacturing (AM) couples traditional wire-based AM for part fabrication and the molten pool metallurgy for material-preparation with high deposition efficiency and material utilization. However, compared with traditional single-wire AM technology, it has a more complex and sensitive dual-droplet transition distance (TD), which not only affects the forming quality but also the metallurgical quality. Therefore, it is necessary and urgent to monitor and control its TD value online. In this study, we systematically investigated the sensing, controlling, and influential mechanism of the TD value in dual-wire AM technology, and Ti₂AlNb was taken as the target alloy owing to its great application prospects in the aerospace field. Specifically, a deposition experiment with different initial TD value was conducted to study the effect on the morphology and composition distribution of the as-printed part. Based on the optimal distance, the related image extraction algorithms and closed-loop control methods are developed. The closed-loop controlled verification experiment on the slope and step substrate, as well as the multi-layer deposition test, were carried out and analyzed. The results indicate that the developed system can control the TD to the desired value with good robustness. In addition, the controlled deposited multi-layer part exhibited good morphology and composition homogenizing in the post-characterization experiment. This study is of great significance for the intelligent and industrial development of dual-wire AM technology.