Parametric influence and effect of cooling channel on bead geometry profiles of ER70S-6 manufactured using wire arc additive manufacturing

Abstract

This study investigated the complex relationship between key process parameters and their effects on weld bead geometrical profile in wire arc additive manufacturing (WAAM) of ER70S-6 low-carbon steel for part production. Specifically, the influence of wire feed rate (WFR), traverse speed (TS), and voltage (U) on weld bead height (WBH), weld bead width (WBW), and weld bead penetration (WBP) was meticulously analyzed. Research methodology integrated the Taguchi technique, analysis of variance (ANOVA), regression modeling, and gray relational analysis (GRA) to investigate and optimize process parameters. Results revealed distinct patterns, with increasing WFR leading to proportional increases in WBH, while elevated TS or U results in reduced WBH due to their impact on arc behavior and heat input. Conversely, WFR and U exhibit notable effects on WBW and WBP, underscoring the importance of optimizing process parameters for desired weld bead geometries. To tackle multi-objective optimization, GRA efficiently determines optimal process parameters for WBH, WBW, and WBP: WFR at 6 m/min, TS at 4 mm/sec, and U at 24 V. Furthermore, the inclusion of a cooling channel beneath the substrate plate significantly influences weld bead geometry, enhancing WBH and WBW while impacting WBP. The cooling channel’s ability to dissipate heat promotes faster solidification, ultimately improving weld bead quality and integrity. These findings offer valuable comprehensions for improving WAAM processes and enhancing the efficiency and quality of part fabrication.