IMPACT 3 – Adaptive Closed-Loop Control of Wire Arc Additive Manufacturing,

This project proposes a real-time, closed-loop control system that continuously adjusts both toolpath coordinates and deposition parameters during the build process, without halting operation. The system will integrate in-situ geometry and radiometric sensors to enable dynamic monitoring and adaptive control based on a hybrid physics-informed and data-driven process model. Initial development will focus on Inconel 625 (IN625), with consideration for Inconel 718 (IN718). The proposed control technology will be applied to a representative DoD-relevant geometry, such as an engine case ring used in aircraft propulsion or turbine systems. These components are mission-critical and currently rely on costly, time-intensive casting or forging. By enabling precision WAAM fabrication and in-process quality assurance, this project directly supports sustainment strategies for legacy and next-generation defense platforms including F-35, B-21, and Army rotorcraft systems.