Optimization of welding process parameters of wire arc additive manufacturing

Abstract

Wire arc additive manufacturing (WAAM) is a cost-effective and efficient method for producing intricate metal geometries. This study employs Design Expert software and the desirability function to optimize WAAM process parameters, focusing on maximizing bead width, height, and microhardness—critical factors determining mechanical properties. Through ANOVA analysis, the research identifies voltage, wire feed speed, and torch speed as significantly influencing welding characteristics. Increased voltage and wire feed speed yield wider beads, while higher torch and wire feed speeds enhance bead height and microhardness. Optimized parameters—16.44 V voltage, 8.99 m/min wire feed speed, and 9 mm/s torch speed—demonstrate precise control over bead properties. This study deepens our understanding of WAAM process parameters, offering valuable insights for consistently producing high-quality weld beads with desired mechanical properties. The findings have profound implications for the manufacturing industry, enabling enhanced efficiency, consistency, and quality in metal component production. Optimized parameters also pave the way for innovative designs, lightweight structures, and rapid prototyping, contributing to the advancement of additive manufacturing, particularly in the context of wire arc technology. This research establishes a foundation for future studies on process optimization, material selection, and widespread WAAM adoption in diverse manufacturing sectors.