The “Arc Welding” research group in Department 9.3 “Welding Technology” is dedicated to research in the field of additive manufacturing using DED-Arc/WAAM. The main objective of the group is the further development of welding technologies, with a focus on the development of efficient methods for the additive manufacturing and subsequent validation of complex metal structures. The integration of state-of-the-art welding techniques with innovative methods of path planning and process optimization serves to improve the precision, efficiency, and flexibility of additive manufacturing systems.

The objective of the proposed master's thesis is to enhance the automated interaction between welding robots and the workpiece during the precise additive manufacturing of thin structures by improving the precision of the scan-based digitalization of the real environment. This will be achieved through the introduction of a novel automatic calibration method, which will replace the existing manual calibration method.

Scope and tasks of the thesis:

  • The literature research on geometric transformations, shape registrations, optimization algorithms, and additive manufacturing using DED-Arc/WAAM
  • The development of a workflow for precise calibration and optimization
  • The creation and optimization of a calibration geometry
  • The validation and quantification of the calibration quality
  • The scientific preparation and writing of a Master’s thesis

Qualifications:

  • Master student in mechanical engineering, electrical engineering, computer science, mathematics or similar
  • Interest or knowledge of mathematical transformations, laser triangulation, robotics, and additive manufacturing with DED-Arc / WAAM
  • Very good knowledge of Python or a similar programming language
  • Experience of working with CAD
  • Experience in working with collaborative software projects using version control systems, preferably GitHub/GitLab
  • Good knowledge of English, knowledge of German an advantage
  • Interest in experimental work and scientific issues

Contact

Michael Winkler
Department of Welding Technology
Phone: +49 30 8104 4363
Email: michael.winkler@bam.de

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