Process and welding parameter studies on influencing continuous welding for Wire Arc Additive Manufacturing

Abstract

Wire Arc Additive Manufacturing (WAAM) is a robot‐controlled, welding‐based additive manufacturing process for producing three‐dimensional steel structures. The technology enables the manufacturing of geometrically complex components that are difficult to realize using conventional manufacturing methods. This article presents a systematic investigation of the influence of selected boundary conditions as well as process and welding parameters on process stability, deposition rate, welding performance indicators, and geometric characteristics of continuously welded layers for a vertical build‐up direction. Fundamental influencing factors are summarized to identify relevant parameters, research gaps, and methodological challenges. Based on this analysis, essential geometric and thermal boundary conditions and associated parameters are derived. A comprehensive parameter study is subsequently conducted using the Cold Metal Transfer (CMT) process variant CMT cycle step (CMT CS). The results are systematically analyzed for influences from the choice of shielding gas, the Travel Speed TS, and the CMT cycle number ncycle specific to the CMT CS process. Recorded welding performance indicators and geometric measurements are compared to provide information about their future applicability and to determine subsequent parameter investigations.