Reinforcement Learning Enabled Intelligent Process Monitoring and Control of Wire Arc Additive Manufacturing

Wire Arc Additive Manufacturing (WAAM) has been recognized as an efficient and cost-effective metal additive manufacturing technique due to its high deposition rate and scalability for large components. However, the quality and repeatability of WAAM parts are highly sensitive to process parameters such as arc voltage, current, wire feed rate, and torch travel speed, requiring advanced monitoring and adaptive control strategies. In this study, a vision-based monitoring system integrated with a reinforcement learning framework was developed to enable intelligent in situ control of WAAM. A custom optical assembly employing mirrors and a bandpass filter allowed simultaneous top and side views of the melt pool, enabling real-time measurement of layer height and width. These geometric features provide feedback to a tabular Q-learning algorithm, which adaptively adjusts voltage and wire feed rate through direct hardware-level control of stepper motors. Experimental validation across multiple builds with varying initial conditions demonstrated that the RL controller stabilized layer geometry, autonomously recovered from process disturbances, and maintained bounded oscillations around target values. While systematic offsets between digital measurements and physical dimensions highlight calibration challenges inherent to vision-based systems, the controller consistently prevented uncontrolled drift and corrected large deviations in deposition quality. The computational efficiency of tabular Q-learning enabled real-time operation on standard hardware without specialized equipment, demonstrating an accessible approach to intelligent process control. These results establish the feasibility of reinforcement learning as a robust, data-efficient control technique for WAAM, capable of real-time adaptation with minimal prior process knowledge. With improved calibration methods and expanded multi-physics sensing, this framework can advance toward precise geometric accuracy and support broader adoption of machine learning-based process monitoring and control in metal additive manufacturing.