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<p>Wire-fed laser additive manufacturing (WLAM) enables the efficient fabrication of large-scale metallic components; however, maintaining a stable layer height remains a fundamental challenge owing to the complex coupling between material feeding and molten pool dynamics. Being a cumulative outcome, layer height inherently exhibits a temporal lag and does not directly reflect instantaneous process variations. To address this limitation, this study introduces wire stick-out as a physically interpretable intermediate observable that captures the dynamic interaction between the feeding wire and the molten pool. A vision-based measurement method is proposed to enable quantitative and time-resolved evaluation of wire stick-out during WLAM. The method integrates robust wire contour extraction with geometry-based spatial reconstruction, supporting the consistent conversion from image-domain observations to physically interpretable measurements. To ensure dependable perception under severe optical interference, a segmentation-based approach incorporating lightweight feature enhancement is adopted to improve contour continuity and robustness. Experimental results demonstrate that the proposed method can consistently extract the wire stick-out profile under varying process conditions, including intense light, spatter, and wire balling. Compared with the baseline model, the proposed method achieves superior contour integrity and markedly enhanced temporal consistency during multi-layer deposition. Furthermore, the measured wire stick-out exhibits low fluctuation during stable deposition and demonstrates a clear correspondence with process state transitions, including the onset of instability. These findings confirm that wire stick-out constitutes a sensitive and dependable process-state variable, bridging the disparity between instantaneous process dynamics and accumulated geometric outcomes. The proposed method establishes a foundation for transforming difficult-to-measure internal process variables into observable quantities, thereby providing a practical basis for future monitoring and control of layer height in WLAM.</p>

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Vision-based wire stick-out measurement method in wire-fed laser additive manufacturing

  • 期刊论文

  • 发表日期：

    2026年5月6日

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  • Guoda Chen,
  • Dingxu Zhou,
  • Yang Gao,
  • Fangda Xu,
  • Beier Wu,
  • Long Ye

摘要

Wire-fed laser additive manufacturing (WLAM) enables the efficient fabrication of large-scale metallic components; however, maintaining a stable layer height remains a fundamental challenge owing to the complex coupling between material feeding and molten pool dynamics. Being a cumulative outcome, layer height inherently exhibits a temporal lag and does not directly reflect instantaneous process variations. To address this limitation, this study introduces wire stick-out as a physically interpretable intermediate observable that captures the dynamic interaction between the feeding wire and the molten pool. A vision-based measurement method is proposed to enable quantitative and time-resolved evaluation of wire stick-out during WLAM. The method integrates robust wire contour extraction with geometry-based spatial reconstruction, supporting the consistent conversion from image-domain observations to physically interpretable measurements. To ensure dependable perception under severe optical interference, a segmentation-based approach incorporating lightweight feature enhancement is adopted to improve contour continuity and robustness. Experimental results demonstrate that the proposed method can consistently extract the wire stick-out profile under varying process conditions, including intense light, spatter, and wire balling. Compared with the baseline model, the proposed method achieves superior contour integrity and markedly enhanced temporal consistency during multi-layer deposition. Furthermore, the measured wire stick-out exhibits low fluctuation during stable deposition and demonstrates a clear correspondence with process state transitions, including the onset of instability. These findings confirm that wire stick-out constitutes a sensitive and dependable process-state variable, bridging the disparity between instantaneous process dynamics and accumulated geometric outcomes. The proposed method establishes a foundation for transforming difficult-to-measure internal process variables into observable quantities, thereby providing a practical basis for future monitoring and control of layer height in WLAM.