Fraunhofer Institute for Production Systems and Design Technology
Fraunhofer Institute for Production Systems and Design Technology

DigiWAAM – Investigating Crack Susceptibility and Inline Monitoring of the WAAM Process Using Digital Methods

International research project in cooperation with the Brazilian CIT SENAI

Crack prevention in additive manufacturing

Additive manufacturing of metals using wire arc welding is becoming increasingly important in industrial applications. The process's high deposition rate enables the production of large-volume components with complex shapes and flexible design options.

However, due to the novelty of the process, standardized test procedures to qualify new materials are not yet available. For example, there are no procedures to determine the susceptibility of materials to cracking during processing. 

Evaluating the susceptibility of materials to cracking in additive manufacturing

Crack test geometry and inline monitoring near the molten pool in WAAM

Temperature range in °C
Plastic strain rate in 1/s

As part of a CORNET project, we investigated the susceptibility to cracking in wire arc additive manufacturing (WAAM) both experimentally and digitally in cooperation with CIT SENAI in Brazil. The goal was to develop a methodology to evaluate cracks in a test component and monitor potential crack formation during the process.

In Germany, a benchmark geometry was studied through finite element simulation of the welding process. Based on these results, the Brazilian partners developed an in-line monitoring system to detect cracks during the build-up process.

Services provided by Fraunhofer IPK

Fraunhofer IPK developed an innovative crack criterion and successfully integrated it into welding structure simulations. Based on this criterion, we designed a specific geometry to evaluate materials in the wire arc additive manufacturing (WAAM) process and optimized it using simulation. Finally, we produced and metallographically validated a test specimen.

This approach combines our expertise in traditional welding technology with advanced welding simulation techniques. Through this approach, we are advancing the development of sustainable, resilient materials and components. It enables us to establish a reliable foundation for the digital transformation of production technology and strengthen the competitiveness of our partners.

Further information

Funding information

The project “Investigation of crack susceptibility and inline monitoring of the WAAM process using digital methods” is funded by the German Federal Ministry for Economic Affairs and Energy as part of the “Industrial Collective Research” program based on a resolution of the German Bundestag. This IGF project 01|F00365C / P1716 of the Forschungsvereinigung Stahlanwendung e.V., Düsseldorf, is being carried out at Fraunhofer IPK, Berlin.