Increasing Heat Input Research Articles

Study on heat transfer and flow of molten pool during the deposition process of laser wire additive manufacturing

In the laser wire additive manufacturing process, the molten pool acts as the critical link between the wire and the deposited part. The heat transfer and flow behavior within the molten pool predominantly determine the quality of the final deposition. Under laser power ranging from 2400 to 3000 W, traverse speeds between 0.01 and 0.04 m/s, and wire feeding speeds from 0.03 to 0.08 m/s, three distinct flow states—single-swirl, double-swirl, and no-swirl—were observed with increasing heat input. Under the optimum process parameters, the molten pool with stable temperature distribution and orderly flow was obtained. In multilayer deposition, the implementation of a laser decay strategy mitigates steep temperature gradients, diminishes the Marangoni effect within the molten pool, and effectively reduces both heat accumulation and lateral flow. Consequently, the flow mode transitions from no-swirl to swirl, and the maximum flow velocity decreases by 40%.

Forming control and the relationship between microstructure and mechanical property in TIG-assisted friction stir welded joint of Ti-6Al-3Nb-2Zr-1Mo titanium alloy

In this paper, T-joints of Ti-6Al-3Nb-2Zr-1Mo titanium alloy were joined with friction stir welding, and microstructure evolution and forming mechanism were studied. The effect of using tungsten inert gas welding to heat additionally the FSW was investigated. Results show a strong effection microstructure of stir zone (SZ) due to the temperature gradient and fast cooling rate. The top and middle sections of SZ have a basketweave microstructure, while there is duplex microstructure at the bottom. When welding at 750 rpm-50 mm/min, the maximum tensile strength of the joint is similar to that of the base metal (BM). As the heat input increases, grain coarsening occurs, which reduces the joint tensile strength and the ability to plastically deform. The fracture mode changes from mixed fracture to ductile one. When TIG-assisted heat source is 20 mm in front of the tool and the power input is in 600 W, the temperature field produced is relatively uniform, which has a positive effect on the weld.

Effect of Heat Input on Tin Bronze-Induced Intergranular Cracks During Arc Cladding Process

This work aimed to figure out the effect of heat input on the characteristics, formation, and elimination of liquid tin bronze-induced intergranular cracks in steel sheets with a thickness of 2 mm. Tin bronze cladding layers were prepared using an arc cladding technique on the steel. A statistical method was adopted to analyze the severity of intergranular cracks. Microstructures and intergranular cracks were characterized by SEM and TEM. The tensile experiments were carried out using an electronic universal testing machine. For the bare steel sheets, the intergranular cracks originated from the cladding layer and propagated into the interior of the steel along the grain boundaries. The intergranular cracks could evolve into macrocracks and lead to the failure of steel. With the increase in heat input, the maximum temperature, maximum stress, and contact time between steel and liquid tin bronze increased. The severity of intergranular cracks was also increased, and the longest crack reached 520 μm. The mechanical properties of the steel sheets decreased with the increase in heat input. For nickel-plated steel sheets, intergranular cracks were eliminated under low heat input, and a transition layer with a nickel content of 12.32 wt.% was generated. The intergranular cracks generated under high heat input and nickel content in the transition layer were only 1.34 wt.%. The strength of the nickel-plated steel also decreased drastically, and the ductility was almost zero.

Numerical simulation of GTAW for ZW61 magnesium alloy thin plates: Coupling the finite element method with the cellular automata method

ZW61 magnesium alloy has a wide range of application prospects as a lightweight green engineering material. In this paper, the temperature field and microstructure of gas tungsten arc welding (GTAW) for ZW61 magnesium alloy are simulated by the finite element method and the cellular automata (CA) method. The results show that the microstructure in the center of the fusion zone (FZ) is all equiaxed grains affected by compositional supercooling. While at the edge of the molten pool, the crystals produced by associative crystallization evolve into columnar grains after undergoing competitive growth. Furthermore, the temperature field of the molten pool alters as the welding heat input increases. Especially, the temperature gradient behind the molten pool slows down. Thus, the cooling rate during solidification of the molten pool decreases, increasing the size of the weld microstructure. Meanwhile, solute concentration plays an essential role in the weld microstructure evolution. The rise in Zn content both refines the size of the equiaxed grains and inhibits the growth of the columnar crystals. Moreover, the experimental results of the thermal cycling curves and the FZ microstructure exhibit minimal error with the simulation results, verifying the reliability of the model.

Effects of heat input on microstructures and mechanical properties of LAZ931 magnesium-lithium alloy in High-Speed TIG welding

LAZ931 magnesium-lithium (Mg-Li) alloy is a novel ultra-light alloy material. This research investigates the Tungsten Inert Gas (TIG) welding process of a 2.15 mm thick LAZ931 magnesium-lithium alloy thin plate without wire filling. The objectives are to determine the appropriate heat input range, achieve welded joints with good forming quality, and examine the effect of heat input on the microstructure and mechanical properties of the welded joints. The results show that post-TIG welding at high welding speed, the melt width of the entire welded joints is very narrow only about 9 mm, and a small amount of MgLiAl2 (θ) phase and AlLi (γ) phase precipitate in the weld seam zone(WSZ), while a significant amount of θ phase precipitates in the heat-affected zone (HAZ), making the HAZ the highest in strength due to precipitation strengthening. With increasing heat input, the quantity of θ phase decreases, resulting in reduced strength and hardness but increased plasticity in the HAZ. The highest hardness in the HAZ was measured at 87.6 HV, with the base material (BM) exhibiting the lowest hardness. The tensile strength of the joint reaches 163.2 MPa, with an elongation of 23.9 %, and the fracture mode is a mixed ductile–brittle fracture.

Effects of stirring friction on the microstructure, texture and mechanical properties of 7055 aluminum alloy

Aluminum alloys are widely used in aerospace, transportation, and many other fields due to their excellent properties such as lightweight, ultra-strength, and high toughness. This paper analyzed the influence mechanism of friction stir on the microstructure, texture, and mechanical properties to realize the strength and toughness of 7055 aluminum alloys and optimize their deformation process. The results show that the aluminum alloys change from uneven banded grains to uniform and fine equiaxed grains after friction stir processing, and the grain size is refined from 14 μm to 0.71 μm. The high-angle grain boundary and texture intensity present an initial increase but a subsequent decrease due to the combined effect of recrystallization and high-temperature softening caused by the heat input of friction stir processing. The total texture intensity and volume fraction of the friction stir processed aluminum alloys decrease significantly, and the intensity of RtG {110} <110>, A {110} <111>, E {110} <111>, and F {111} <112> texture significantly decrease or disappear, while the Brass (B) {110} <112> texture increases. The yield strength of FSP aluminum alloys decreases with increasing heat input (w/v), which mainly depends on the weakening of the texture strengthening effect. However, the increase of geometrically necessary dislocations (GND) caused by grain boundary sliding leads to the significant improvement of the deformation hardening ability and plasticity of the material. In addition, the effect of texture on the plasticity of aluminum alloys was calculated by using Schmid law. It is found that the equivalent slip factor (ESF) and maximum Schmid factor (μmax) of A, E, and Cu textures are equal to 0. The small ESF and μmax of the S texture are not conducive to the plastic deformation property of materials, while the 1000 × 70 sample with more ESF (8) and μmax (0.41) of the Cube texture ({001} <100>) shows better plasticity.

Effect of different heat inputs on the microstructure and mechanical properties of the laser welded joint of CLF-1 steel

Abstract In this study, we examined the effects of various heat inputs on the microstructure and mechanical properties of the laser-welded joints of CLF-1 low-activation ferritic/martensitic steel medium-thick plates, which are used in the Test Blanket Module (TBM). The results indicate that under four different welding heat inputs (2727 J/cm, 3000 J/cm, 3563 J/cm, and 4500 J/cm), the weld microstructure is primarily composed of a large amount of lath martensite and a small amount of δ-Fe. As the heat input increases, the average width of lath martensite in the weld microstructure progressively increases, while the average volume fraction and width size of δ-Fe experience a significant increase. When the heat input surpasses 3563 J/cm, δ-Fe exhibits a dense aggregation. The tensile properties of the joints created under different heat inputs are superior to those of the base material. At the lowest heat input, the maximum impact toughness of the weld reaches 40 J.

Influence of arc energy on the microstructure and corrosion behavior of ER2209 duplex stainless steel deposited on Q345B low-alloy steel by GMAW

In order to eliminate the complex effects of thermal cycling and the thermal effects of the next pass on multi-layer multi-pass welding of low-alloy steel and duplex stainless steel, ER2209 welding wire was single-layer single-pass deposited on the surface of Q345B hot-rolled plate by gas metal arc welding (GMAW). The microstructure and corrosion resistance of welded joints were studied by different arc energies. The results showed that the arc energy had a significant impact on the “tongue-shaped” morphology and the width of heat affect zone in the welded joint, which in turn affected the corrosion performance of the welded joints. Due to the least distribution of “tongue-shaped” morphology and minimum width of heat affected zone in the welded joint with arc energy of 0.645kJ/mm, it owned the best corrosion resistance. The weld metals of the welded joints were composed of ferrite and austenite phases. The ferrite phases were distributed along grain boundaries and intergranular. As the heat input increases, the distribution of ferrite phase along grain boundaries gradually decreased. The corrosion products and corrosion morphology of the welded joint were also investigated and the corrosion mechanism was discussed in detail. The research results of this article provide a theoretical basis for improving the corrosion performance of multi-layer multi-pass welded joints of low-alloy and duplex stainless dissimilar steels.

Performance analysis of various fluxes in different variants of the TIG welding process on the quality of welding

The tungsten inert gas (TIG) welding process is widely used in various industries for its ability to produce high-quality welds at a low cost. However, TIG welding struggles with welding thick stainless steel in a single pass, reducing production efficiency. To address this, new TIG variants such as activated TIG (A-TIG), flux bound TIG (FB-TIG), and flux zone TIG (FZ-TIG) have been developed to enhance penetration in austenitic stainless steel. This study investigates the effects of TiO2 and Fe2O3 flux on 304 stainless steels welded using A-TIG, FB-TIG, and FZ-TIG processes. Results show a slight increase in the depth-to-width (d/w) ratio for A-TIG and FB-TIG, while FZ-TIG achieved a 59% higher d/w ratio compared to autogenous TIG welding. The increased penetration is attributed to the reversal Marangoni convection and arc constriction. Microstructural analysis reveals a higher delta ferrite content in A-TIG and FZ-TIG welds due to increased heat input. Additionally, FZ-TIG welds exhibited an 11.5% higher microhardness compared to autogenous TIG welds. FZ-TIG welding enhances penetration and mechanical properties effectively.

Research on the Microstructures and Properties of AA5052 Laser-Welded Joints with the ER4043 Filler Wire

Researches were conducted on the laser welding of 3 mm sheet-thickness lap joints of AA5052 with ER4043 filler wires. The effects of laser power on the joint morphology, microstructure, mechanical properties, and corrosion resistance were investigated. The results indicate that both increased heat input and the addition of filler wires make the molten pool more instable, which results in more process pores. Circular pores are observed in the upper part of the weld, while chain-like pores are distributed in the middle of the weld. The highest tensile strength of the weld joint is 192.61 MPa with an elongation of 10.1% at a laser power of 3.5 kW. The microhardness at the center of the weld is approximately 25% higher than the base material, which is probably because the addition of ER4043 filler wires brings more Si element to the weld. Moreover, the weld joints display superior corrosion resistance compared to the base material. These outcomes enhance the understanding of AA5052 laser welding with fillers wire and provide valuable in-sights for engineering applications.

Effect of temperature and heat input on helium isotope separation driven by an entropy filter

To understand the effect of temperature and heat input on helium isotope separation driven by an entropy filter, the thermomechanical flow of superfluid helium through an entropy filter for obtaining high purity 4He is experimentally investigated. For this method, there are two important indicators: separation flow (flow rate) and separation effect (3He concentration). The separation flow rate is examined at various temperatures ranging from 1.6 K to 1.9 K of feed helium. Different heat inputs (Q) are applied to the entropy filter outlet to drive superfluid 4He flowing through the porous element. The results demonstrate that the flow rate increases as the feed helium temperature decreases and heat input increases. Simultaneously, 3He diffusion is detected as the superfluid helium passes through the entropy filter. The concentration of 3He, filtered at different temperature ranging from 1.6 K to 1.9 K, are analyzed using HELIX SFT Static Vacuum Mass Spectrometer. The findings reveal that the 3He concentration decreases with an increase in the temperature of the feed helium bath. 3He concentration of feed helium is around 3.3×10-8. Specifically, the 3He concentration in the filtered helium at 1.6 K is approximately 3.2×10-10, while at 1.9 K, it reduced to 2.2×10-10. This suggests that 3He diffusion in He II is inversely proportional to the He II temperature from 1.6 K to 1.9 K, resulting in a lower 3He concentration at higher temperatures.

Machine learning-assisted wire arc additive manufacturing and heat input effect on mechanical and corrosion behaviour of 316 L stainless steels

Predicting the track forming factor or height-to-width ratio (H/W) in wire arc additive manufacturing is crucial for optimal path planning, heat distribution, structural integrity, distortion control, process efficiency, and defect prevention, ensuring high-quality and reliable components. Different analytical and numerical modeling methods have been introduced to predict the H/W ratio. However, the accuracy of these predictions is relatively low due to the challenges associated with handling complex and non-linear regression equations. This study addressed the challenges by implementing data-driven predictive modeling to predict the H/W ratio from the input process parameters. A stacking ensemble learning approach is employed, where a meta-model integrates predictions from multiple base learners to enhance overall performance. The model performance was evaluated by Coefficient of determination (R2), mean squared error (MSE), and mean absolute error (MAE). The model was validated by comparing the experimental and predicted values based on which five thin walls are printed with different heat inputs. The study also explores the impact of heat input on microstructure, mechanical, and corrosion properties. The findings indicate that a significantly low heat input (178 J/mm) and higher heat inputs (> 356 J/mm) decrease the wire utilization. With increasing heat input, ferrite content increases, microstructures become coarser, dendritic spacing increases, and ferrite transitions from lathy to skeletal. Further, lower heat input (235 J/mm) reduces δ-ferrite, suppresses atomic segregation, and increases Cr and Mo in the matrix. YS and UTS decrease with higher heat inputs, anisotropy decreases, and Vickers microhardness drops from 228 (178 J/mm) to 194 Hv (586 J/mm). Additionally, the corrosion resistance deteriorates with increasing heat input, as evidenced by higher pitting potential (Epit: 0.389 V vs. 0.368 V vs. −0.023 V) and lower corrosion current density (Icorr: 6.76 ×10−7 A/cm2 vs. 7.946 ×10−7 A/cm2 vs. 8.91 ×10−7 A/cm2) for heat inputs of 235 J/mm, 281 J/mm, and 356 J/mm, respectively.

Additive manufacturing of functionally graded stellite6/17-4 PH fabricated via direct laser deposition

Multi-material structures with variable functionalities can lead to unique solutions for engineering problems compared to single-material structures. Additive manufacturing of Functionally Graded Materials (FGMs) using Direct Laser Deposition for the multi-material deposition of Stellite6 and 17–4 PH stainless steel has been investigated in this study. Process parameter design was successfully applied to achieve FGM structures with expected composition ratio and defect free. Results revealed that clads with insufficient laser power had unmelted 17-4 PH powders, while those with excessive power resulted in micro-cracks and disrupting the expected composition for the previous layer. Energy Dispersive Spectroscopy analysis results showed that the composition was almost as expected, with less than 10% deviation. The Stellite6 composition in FGM exhibits a minimum ratio near the substrate due to the penetration of 17-4 PH elements. Meanwhile, in multi-track clads, the Stellite6% decreases along the transverse direction due to increased heat input, multiple cladding tracks, higher dilution, and slower solidification rate. The results of the micro-hardness tests illustrated the gradual evolution of micro-hardness along the build direction starting from the base metal, which had a hardness of approximately 300 HV for 17-4 PH and for the compositions of 25%, 50%, 75%, and 100% Stellite6 showed increases of 10%, 39%, 43%, and 63% respectively, reaching up to 490 HV for fully Stellite6 at the top of the specimen.

Effect of Laser Heat Input on the Microstructures and Low-Cycle Fatigue Properties of Ti60 Laser Welded Joints

In this paper, the effects of laser heat input on the microstructures, tensile strength, and fatigue properties of Ti60 laser welded joints were investigated. The results show that with the increase in laser heat input, the macro morphology of the weld zone (WZ) changes from the Y-type to X-type. In the Y-type WZ, the porosity defects are almost eliminated. In contrast, there are a lot of porosity defects in the lower part of the X-type WZ. The microstructure of the base metal (BM) comprises equiaxed α phases, and β phases are mainly distributed at the boundaries of α phases. The heat-affected zone (HAZ) is comprised of α phases and acicular α′ phases, while the WZ mainly contains acicular α′ phases. With the increase in laser heat input, the quantity of the α phase gradually decreases and the acicular α′ phase gradually increases in the HAZ, and the size of the acicular α′ phase in the WZ gradually decreases. Due to the different microstructures, the hardness of BM is lower than the HAZ and WZ under different laser heat input conditions. In the tensile tests and low-cycle fatigue tests, the welded joints are fractured in BM. The porosity defects do not have decisive effects on the tensile and low-cycle fatigue properties of Ti60 laser welded joints.

Insights into two-phase flow dynamics in closed-loop pulsating heat pipes utilizing Fe3O4/water: experimental visualization study

This article discusses a focused study on visualizing the flow patterns in a two-phase pulsating heat pipe (PHP) using Fe3O4/water as the working fluid at 3 V/V% concentration. The research also aims to meticulously examine phase change phenomena in the heating section, particularly focusing on bubble formation and expansion processes. A high-speed video camera was utilized to capture dynamic insights into the behavior of the Fe3O4/water mixture. Based on the findings, a straightforward model was developed to explain bubble generation and growth in the mixture, serving as a useful reference for future PHP designs and optimizations. Visual observations also noted the stable nature of the Fe3O4/water nanofluid over a 4-day period, confirming its consistency throughout the experiments. Moreover, the impact of heat load variation on the evaporator section was assessed using controlled heat inputs ranging from 10 to 80 W. Observations on the arrangement of slugs and plugs at a 50% filling ratio revealed interesting self-adjusting flow patterns in response to increasing heat inputs, providing valuable insights into PHP operational dynamics. Notably, the oscillatory flow behavior of Fe3O4/water, the chosen working fluid, exhibited greater activity in comparison to water. This distinctive flow behavior contributed to achieving heightened thermal performance efficiency for the Fe3O4/water system, attributed to its faster attainment of the annular flow condition.

Effects of Heat Input and Intertrack Overlap on the Microstructure and Properties of Inconel 686 Weld Overlays.

The objective of this study was to investigate how weld overlays with nickel superalloys are important for the integrity, due the high temperatures and corrosive environments that can be experienced in mineral processing environments, of mining and processing equipment. The Ni-Cr-Mo superalloy Inconel 686 overlays are fabricated through automatic gas metal arc welding with variations in arc voltage and travel speed (i.e., heat input), and they have overlap between adjacent weld tracks for applications in the mining and minerals sector. The impact of variations in the process parameters and the size of the weld overlapping on the dilution, solidification morphology, microsegregation, and microhardness were investigated. Both geometric and chemical composition definitions were used to quantify the extent of the weld dilution. Subsequently, the weld geometry and dilution were correlated with the solidification microstructure and phase transformations. The maximum dilutions were measured to be 13.63% (1/2 overlap, 5.96 kJ·cm-1) and 15.39% (1/3 overlap, 4.77 kJ·cm-1), which shows that less of an overlap increases the dilution level. Scanning electron microscopy and chemical composition analysis revealed that an increase in weld heat input and dilution level led to higher levels of microsegregation for Mo and Cr, as well as the volume fraction of Mo- and Cr-rich phases in the interdendritic/intercellular regions in the overlay layer. Analysis of the weld overlays in the current study revealed strong and unprecedented connections between the weld overlay process conditions, the resultant metallurgy (i.e., dendrite arm spacing, microsegregation, and phase formation), and the hardness of the overlay. It was concluded that the optimal weld overlays in the processing window studied in this investigation were fabricated at mid-level heat inputs (i.e., 4-5 kJ·cm-1) and a 1/2 track overlap.

Development of Microstructure on Titanium Implant Surface Using CO2 Laser Processing

Background: Dental biomaterials made of titanium are commonly used. It depends on the implant surface texture to improve fixation and prevent the unwanted adhesion of bone cells. This study aimed to investigate whether continuous laser beam carbon dioxide (CNC - CO2) lasers produce specific textures on titanium surfaces with micrometer-sized indentations that influence cell behavior. Materials and method: (CNC - CO2) red laser device; with a fundamental wavelength of λ=10600 nm and power pulses of 34 W were applied, and textures on the surface of titanium discs were achieved. Results: Excellent degrees of uniformity and repeatability were achieved for the desired portions of the surface by creating different surface textures. The surface topography and chemical composition of the specimens were investigated by scanning electron microscopy, electron dispersive spectroscopy, X-ray diffraction, and surface roughness measurements. Also, a laser power of 34 watts raised the surface roughness, Ra (1.71 nm), and Rz (1.99 nm). Conclusion: Titanium surface textures with unique qualities can be formed in response to an increased heat input. When excessive laser power was used, the measured roughness increased because of instantaneous re-melting. The use of a right continuous-wave (CNC - CO2) laser on titanium used in dental implants can form specific surface textures.

Thermal hydraulic behavior of a large dimension hybrid heat pipe/oscillating heat pipe

Similar to the layout of an oscillating heat pipe (OHP), a quartz hybrid heat pipe (HHP) with an inner diameter of 5 mm, exceeding 59.7 % of the capillary threshold of OHP, was designed. The detailed thermal hydraulic behavior of fluid in the HHP has been revealed. It was found that the HHP undergoes a heat transfer mode transition from phase change to pulsating flow. It is also means that the liquid slugs can be dynamically and stably formed if the heat input is sufficient. The single bubble growth and the multi-bubble coalescence are two ways to form the intermittent flow. In addition, as the main flow pattern in low filling ratio (FR), the formation of annular flow is closely concerned in the behaviors of fluid. Moreover, the higher the FR is, the clearer the contour of slug flow is. At the same time, the oscillating motion can be formed easily at a high FR, resulting in a better performance of HHP in lower heat load. However, as the heat input increases, HHP with a 60 % filling ratio exhibits lower thermal resistance, achieving a minimum value of 0.08 °C/W at 100 W.

Effect of alloy 625 buffer layer on corrosion resistance of nickel base hardfacing

Nickel base hardfacing alloys serve to mitigate corrosion losses at elevated temperatures. Efficacy of Nickel base hardfacing alloys can be compromised when applied onto Fe base substrates due to iron dilution in hardfacing. The degree of Fe dilution can be reduced by using advanced deposition methods and optimized deposition parameters. Gas Tungsten Arc Welding (GTAW) method is commonly employed for its cost-effectiveness and versatility, but it tends to induce higher Fe dilution due to increased heat input. This study aims to reduce the degree of Fe dilution and enhance corrosion resistance by introducing a nickel base buffer layer (alloy 625) between the nickel base hardfacing alloy and AISI 316L stainless steel substrate. For comparative purposes, Ni base hardfacing alloy was deposited on the substrate without any buffer layer. Hardfacing depositions were prepared using manual GTAW process. Process parameters namely, deposition current, voltage, travelling speed, pre-heating temperature, and cooling method were kept constant. Samples underwent aging at 1123 K for 4 h, followed by microstructural examination via optical and scanning electron microscopes. Iron (Fe) dilution quantification was performed using energy dispersive spectroscopy (EDS). The EDS analysis showed that the use of buffer layer between the hardfaced deposit and the substrate decreased the degree of Fe dilution in the hardfaced deposit. X-Ray diffraction (XRD) analysis was performed to identify various phases formed in the hardfaced deposit. Potentiodynamic polarization test was performed to assess the corrosion resistance of hardfaced deposit in 3.5 wt% NaCl solution. Results show significant improvement in corrosion resistance of hardfacings deposited sample with buffer layer as compared to those without buffer layer. Aging treatment further enhanced corrosion resistance. The corrosion resistance data is correlated with the microstructure and phases formed in various samples.

Effect of heat input on bead geometry and mechanical properties in wire arc additive manufacturing of a nickel aluminum bronze alloy

Wire arc additive manufacturing (WAAM) stands as an efficient and cost-effective method for producing large-scale engineering components while minimizing waste. This study explores the influence of WAAM process parameters on nickel aluminum bronze (NAB) parts, focusing on the wire feed rate (WFR) as a key factor governing heat input and its effects on bead geometry, microstructure, and mechanical properties. The investigation involved depositing a single bead from NAB alloy while varying the WFS within the 2–7 m/min range, resulting in heat inputs ranging from 20.600 to 57.960 kJ/m. The results revealed that increasing heat input up to 34.944 kJ/m led to an augmentation in the bead dimensions and increased hardness due to κ-precipitates formation within the α-Cu matrix. However, with further increments in heat input to 49.088 kJ/m and 57.960 kJ/m, the bead dimensions and hardness exhibited a decline as the uniformity of intermetallic κ distribution lessened. Through optimization of WAAM process parameters, a defect-free single-wall NAB was successfully manufactured with enhanced properties. The tensile strength along the horizontal direction for the single-wall NAB alloy was found to be superior to that of the vertical direction, irrespective of the specimen's extraction regions. Additionally, the bottom specimen exhibited slightly higher tensile strength than the center and upper specimens due to being the initial layers of the wall deposited on the substrate plate, undergoing a faster cooling rate. These findings underscore the potential of WAAM as a robust method for the fabrication of larger NAB components with precision and efficiency.