Abstract
This paper presents investigations on the manufacturing of three-dimensional functional metallic parts through melting and deposition of stainless steel 430L wire material by a metal inert gas welding technique. Experiments were performed on wire arc additive manufacturing following face centered composite design of experiments considering voltage, current, electrode wire material feed rate and welding speed as inputs for modeling single bead geometry in terms of bead width, height, and cross-sectional area. Response surface models were built using the collected experimental data. Performance of the models in predicting the responses was found satisfactory. Models of single bead geometry were employed to calculate void and post-processing in fabricating three-dimensional parts following raster scanning deposition of multiple layers considering the different degree of overlapping and build directions. The theoretically estimated values of void and post-processing were verified through fabrications of two three-dimensional shapes. It was shown that the void and post-processing could be controlled by suitable selection of process parameters, the degree of overlapping between two beads and build direction.
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