doi: 10.52899/24141437_2025_04_513
UDK: 621.791.927.5

Manufacturing of Arc Torch Interface for Robotic Arm Flange Using Arc-Directed Energy Deposition

Рощин Н. Д., Насоновский К. С., Волосевич Д. В., Корсмик Р. С. Article language:
Citation Link: Roschin ND, Nasonovsky KS, Volosevich DV, Korsmik RS. Manufacturing of Arc Torch Interface for Robotic Arm Flange Using Arc-Directed Energy Deposition. Transactions of the Saint Petersburg State Marine Technical University. 2025;4(4):513–522. DOI: 10.52899/24141437_2025_04_513 EDN: HLMCBP

Annotation

BACKGROUND: Additive manufacturing involves the creation of three-dimensional objects with layer-by-layer application of additive material. There are many additive manufacturing technologies, each differing in consumables, manufacturing speed, surface quality of the resulting sample, power source, etc. One of these is the arc-directed energy deposition technology. Arc-directed energy deposition is an additive manufacturing technology that uses electric arc energy as a heat source to melt additive material. It is widely used in contemporary mechanical engineering due to its high productivity and wide range of materials, especially in the manufacturing of special equipment and components of complex shapes, where conventional techniques are not effective enough. AIM: This work aimed to design, manufacture, and test an arc torch Interface for an industrial robotic arm flange using arc-directed energy deposition. METHODS: We used welding wire made of AlMg5 alloy and high-purity argon as a shielding gas. For manufacturing, we used a process system based on a Fanuc M-710iC robot arm and a Fronius TPS500i welding power source with a cold metal transfer capability. Experiments were conducted to select manufacturing conditions and strategies to ensure high quality of the test piece and minimize defects. The manufactured pieces underwent metallography and mechanical tests. RESULTS: A range of standard manufacturing conditions has been selected. The chosen manufacturing strategy allowed to reduce anisotropy and avoid incomplete fusion. Mechanical tests showed that the properties of the deposited material exceed the requirements of GOST 17232-99. The study allowed to design, manufacture, and assemble an interface that meets the specified rigidity and dimensional criteria. CONCLUSION: The study showed the effectiveness of manufacturing arc torch interfaces for robotic arm flanges using arc-directed energy deposition. The developed method allows to manufacture complex shape products with the required mechanical properties, which corroborates the potential of arc-directed energy deposition in mechanical engineering. Keywords: additive manufacturing; arc-directed energy deposition; interface; cold metal transfer; tooling; robotic arm; AlMg5.

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