A dataset for "Characterizing power output, thermal evolution, and bead geometry in wire arc additive manufacturing under power-regulated arc control"

This study investigates the influence of power and wire feed speed (WFS) settings on power output, thermal conditions, and geometric outcomes in wire-arc DED under constant-power control. Unlike conventional wire-arc DED setups which employ constant-voltage or constant-current settings, the constant-power setting introduces dynamic process behavior which has been underexplored in existing literature. Through 9 multi-bead, multi-layer builds and 49 single-bead experiments, the effects of the power and WFS settings on the measured output power are investigated, as well as how these parameters, in turn, influence mid-process bead heights, build temperatures, and substrate temperatures. Additionally, the evolution of the build’s interpass temperature and several substrate locations’ temperatures are tracked, and the varying relationships between these temperatures are assessed throughout the builds’ progression. The study’s breadth of experiments enables a statistically grounded exploration of heat accumulation and bead geometry formation for a unique power control mode, under realistic wire-arc DED conditions.

Dataset information:
- Study_parameters.jpg gives the 9 multi-layer builds' WFS and power settings.
- P_output_analysis_data.csv gives the data for the analysis of the system's output power values and their deviations from the power setting, based on various WFS and power settings for single beads.
- build_heights_dict.npy & bead_heights_dict.npy give the build and individual bead height values at each "image point" (the X-Y coordinates of the torch when an individual IR image was taken). These Numpy files contain python dictionaries with all of the build and bead height data for all 9 of the multi-layer experiments. The keys in the dictionaries are based on the experiment and layer numbers, and each key's value is a 6x120 array-- 6 beads x 120 image points going across each bead. The 120 image points' height values are in order from -X to +X, not in the order in which all of the beads were deposited. The 6 beads are in the order in which they were deposited-- +Y to -Y.
- Each experiment's "mean_temps_whole_experiment.npy" file includes an 8x6x140x720 Numpy array. The 1st & 2nd dimensions represent the experiment's 8 layers & 6 beads. The 140-dimension represents the 120 images which were taken during each bead, plus the 10 images from before & after that bead's deposition, and they are listed in order. The 720-dimension represents the total number of image point locations (incl. all 6 beads) which are present on the current layer.
- The "mean_temps_substrate_locations.npy" files each include a 8x6x140x8 array. The last dimension of this array represents the temperatures of 8 locations on the substrate's top surface. Substrate_locations.png gives the coordinates of these locations on the substrate, relative to the origin which is set at the -X, -Y top corner of the substrate plate.