Robotic Integration and Process Control for WAAM and SiC/SiC Laser Joining

The continuous advancement of engineering applications, particularly in the aerospace, energy, and materials research sectors, has led to a growing demand for precision manufacturing techniques that enable localized control, geometric complexity, and material flexibility. This thesis presents the development and experimental validation of a robotic platform built around an ABB IRB 2400 industrial manipulator. The system was configured to support two distinct advanced manufacturing workflows: laser-assisted joining of ceramic matrix composites (CMCs) and Wire Arc Additive Manufacturing (WAAM) using Cold Metal Transfer (CMT). The primary goal was to create a modular, reprogrammable infrastructure for laboratory-scale fabrication tasks requiring automation, repeatability, and process flexibility. The first phase of the project focuses on joining tubular SiC/SiC ceramic components using a localized laser heat source in combination with active mechanical pressure. A linear actuator was integrated into the test setup to apply controlled axial force during the laser process. A custom housing bearing was fitted at the actuator’s tip to ensure free rotation and smooth contact with the tube, and a 3D-printed prototype was used to validate the configuration. Process conditions were monitored through coaxial vision and thermal imaging, and resulting joints were characterized via microscopy, computed tomography, and mechanical testing. In the second phase, the robot was reconfigured for WAAM experiments using a Fronius TPS 400i CMT welding source. The robotic cell was equipped with the ABB 3D Printing PowerPac and ArcWelding modules to interpret G-code paths and convert them into executable RAPID routines. Slicing was performed in Cura with custom parameters to create linear and hexagonal geometries. A structured Design of Experiments (DOE) was carried out by varying wire feed speed and robot travel speed while keeping a constant synergic arc curve, enabling the evaluation of deposition quality in single pass bead trials. These tests revealed a stable process window, which was later validated through multi-layer builds. Overall, the system demonstrates that combining industrial robotics, modular tooling, and simulation-driven programming provides a powerful and adaptable platform for both joining and additive processes. This approach allows for high configurability and precise coordination between motion and material interaction, laying the groundwork for further development of hybrid and closed loop manufacturing systems in research oriented environments.