Single Welding Research Articles

The mechanism study of TIG-MIG hybrid welding process based on simulation

Tungsten inert gas-metal inert gas (TIG-MIG) hybrid welding combines the advantages of tungsten inert gas (TIG) welding and metal inert gas (MIG) welding. Due to the benefits of the two welding techniques, it is an effective strategy to enhance welding quality and productivity. To investigate the mechanism of arcs interaction in TIG-MIG hybrid welding, a three-dimensional transient model for arc-droplet-weld pool behavior was established. The temperature field, metal vapor content, flow fluid, current density and electromagnetic force in the arc space and weld pool were simulated and analyzed. The calculation results showed that the introduction of the TIG arc decreased the content of metal vapor and increased the arc temperature. Compared with single MIG welding, the amplitudes of maximum arc temperature and plasma velocity in TIG-MIG hybrid welding were lower. Experimental results demonstrated that the droplet deflection angle, droplet transfer frequency, weld bead cross-section, and arc temperature distribution all agreed well with calculated values.

Influence of process parameters on single weld seam geometry and process stability in Laser Hot-Wire Cladding of AISI 52100

Steels with high carbon content can hardly or not at all be welded, but are of great interest for cladding applications due to their high hardness. In this study, the influence of process parameters on weld seam geometry and process stability is investigated when welding AISI 52100 bearing steel using the laser hot-wire cladding process. Process stability is evaluated using actual and set values for the wire feed rate and current parameters to determine a process window for a stable welding process. Weld seams are measured and analyzed in terms of width, height, contact angle, and shape. The effect of the process parameters on the weld seam geometry is investigated and appropriate mathematical functions to describe the geometry are determined. Process parameter sets in the range of 1-2 m/min wire feed rate and 45-75 A hot wire current were investigated. Unstable parameter sets occur clustered at high wire feed rate of 2 m/min for all hot wire currents. In addition, the process is unstable at high hot wire current of 75 A and low wire feed speed of 1 m/min. The remaining parameter sets resulted in a stable process. The investigated functions parabolic, cosinusoidal and circular arc for the mathematical description of the weld seam geometry, no clearly significant result could be determined. Only a trend towards the circular arc function and the parabolic function is apparent.

Investigation of resistance spot weld failure in tailor hot stamped assemblies

A novel experimental method, dubbed the “Mode I Caiman test”, is introduced to characterize spot weld failure and propagation within spot weld groups. The test configuration comprises a partially welded pair of channel sections subjected to Mode I tensile loading through an opening mode loading applied at the un-welded end of the channels. Experiments were performed considering hot stamped USIBOR® 1500-AS in a fully hardened condition (fully quenched) or in a tailored condition in which the strength of the welded flanged regions was altered using in-die heating (IDH). Both static and dynamic loading conditions are considered. The static loading utilized a conventional tensile frame while the dynamic experiments were performed on an instrumented crash sled at velocities of 7.5 m/s.A high speed thermal imaging camera was utilized to detect the temperature rise associated with plastic work during individual weld failure. This proved to be a rather novel and effective technique to detect weld failure and enabled tracking of weld failure propagation through the weld group for the different parent metal (flange) conditions.The experiments served to demonstrate the complex interaction between weld nugget, heat affected zone (HAZ) and parent metal strengths. For high parent metal strengths (fully quenched, martensitic condition), the welds exhibited interfacial and weld pull-out failure modes with rapid unzipping of the weld group resulting in relatively low energy absorption. In contrast, the lower strength tailored flanges exhibited a more stable (slower) failure propagation through the weld group and considerably higher energy absorption which is largely attributed to greater dissipation through deformation of the flange itself. Numerical simulations of the experiments were performed using spot weld models calibrated from single weld lap shear, cross tension, and coach peel experiments. The models captured the peak loads rather well, but predictions of rate of failure propagation within the weld line exceeded that seen in the experiments, pointing to the need for improved post-failure models for spot weld simulation.In automotive structures in which numerous welds are present, the amount of energy absorbed in weld failure can significantly affect the impact response of the structure. The Mode I Caiman test presents a new opportunity to calibrate the energy release rate of spot weld damage models to improve their accuracy when modelling spot welded connections involving multiple spot welds.

Influence of Novel Beam Shapes on Laser-Based Processing of High-Strength Aluminium Alloys on the Basis of EN AW-5083 Single Weld Tracks

The commonly used Gaussian intensity distribution during the laser-based processing of metals can negatively affect melt pool stability, which might lead to defects such as porosity, hot cracking, or poor surface quality. Hot cracking is a major factor in limiting production rates of high-strength aluminium alloys in laser-based processes such as welding or the powder bed fusion of metals (PBF-LB/M). Going away from a Gaussian intensity distribution to ring-shaped profiles allows for a more even heat distribution during processing, resulting in more stable melt pools and reduced defect formations. Therefore, the aim of this study is to investigate the influence of different laser beam profiles on the processing of high-strength aluminium alloys by using a multicore fiber laser, allowing for in-house beam shaping. Single weld tracks on the aluminium alloy EN AW-5083 are produced with varying laser powers and weld speeds, as well as different beam profiles, ranging from Gaussian intensity distribution to point/ring profiles. The molten cross sections are analyzed regarding their geometry and defects, and the surface roughness of the weld tracks is measured. By using point/ring beam profiles, the processing window can be significantly increased. Hot cracking is considerably reduced for weld speeds of up to 1000 mm/s compared to the Gaussian beam profile. Furthermore, the melt pool width and depth are more stable, with varying parameters for the point/ring profiles, while the Gaussian beam tends to keyhole formation at higher beam powers. Finally, a strong decrease in surface roughness for the point/ring profiles, accompanied by a significantly reduced humping effect, starting even at lower beam powers of 200 W, can be observed. Therefore, these results show the potential of beam shaping for further applications in laser-based processing of high-strength aluminium alloys.

Effects of Welding Parameters on Sigma Phase Precipitation in 25Cr-5Ni-1Mo-2.5Cu-1Mn-0.18N Duplex Stainless Steel

Recently, a new grade of duplex stainless steel, UNS S82551 (25Cr-5Ni-1Mo-2.5Cu-0.18N), has been developed to overcome the drawbacks in super martensitic stainless steel, conventional 22Cr and 25Cr super duplex stainless steels in terms of productivity and cost. The characteristic of the alloy design of UNS S82551 is to use Cu, instead of Mo, to ensure comparable corrosion resistance and strength. In addition, due to the significant decrease in Mo content, UNS S82551 is expected to be less sensitive to sigma phase precipitation during single or multi-pass welding compared with conventional and super duplex stainless steels. There is a trade-off between achieving better properties and avoiding sigma phase precipitation when increasing alloying elements such as Mo, Cr and Cu. In order to utilize the new UNS S82551 steel in industry for welding in a similar manner to conventional and super duplex stainless steels, the prevention of sigma phase precipitation is important. This work investigated the effect of weld thermal cycling on sigma phase precipitation behaviour in UNS S82551 welds. During thermal cycling in the tests, the amount of sigma phase for UNS S31803 and UNS S32750 increased with increasing the number of thermal cycles, and lower cooling rate, but it was not observed for UNS S82551. Based on the isothermal kinetics of sigma phase precipitation, the amount of sigma phase precipitated during thermal cycle can be predicted by applying the additivity rule to the physical model. The area fractions of sigma phase calculated have a good fit to the experimental ones.

Fatigue cracking characteristics of components stiffened with vertical ribs under eccentric loading in steel bridge deck

The components in orthotropic steel decks are generally in an eccentrically loaded state for the nonuniformly distributed wheel loads. By conducting numerical simulation and fatigue tests of components stiffened by the vertical rib (CVR) with single butt weld, the propagation law of CVR cracks under eccentric loading were analyzed. By comparing with components stiffened by U-ribs (CUR), the difference of crack-growth characteristics between components with single and multi butt welds under eccentric loading was explored. The results show that CVR cracks will initiate at the eccentrically loaded side of the weld and propagate obliquely, but still perform the bilateral cracking mode as that under symmetric loading. The CUR and CVR cracks present the same three-stage characteristics of fast-slow-rapid growth and components will accelerate to failure in the third stage, which shall be avoided. The section-damage rate of CUR will be greatly relieved for the unilateral cracking under eccentric loading compared with that of bilateral cracking under symmetric loading, which delays the crack to enter the rapid-growth stage. Since there’s little effect of eccentric loading on the demarcations of crack-growth stages in CVR, it is reasonable to take the demarcation 80 mm between the second and third crack-growth stages as the warning length for maintenance. The semi-elliptical CVR cracks will quickly penetrate base metal after extending to 75 % of thickness with the average ratio of crack depth to length being 0.09, which can be treated as the operation timing of maintenance methods for non-penetrating cracks.

Numerical simulation research on welded residual stress and distortion of aero-engine afterburner lobe mixer with different welding sequences

Most thin-walled parts of aero-engines with intricate surfaces, such as lobe mixer, are welded using tungsten inert gas (TIG), which will certainly induce stress and distortion, causing a serious influence on assembly accuracy. The objective of this study was to establish a finite element model to optimize TIG wire filler welding sequence for an aero-engine lobe mixer composed of GH3044 nickel–based superalloy at the thickness of 2 mm. A new method for optimizing residual stress and distortion in the welding of large-size components was proposed. We carried out a 2-mm-thickness plate TIG wire filler welding experiment to obtain the ideal process parameters and validate the heat source model and thermal boundary condition, and also designed a set of frock clamp. The stress and distortion of the lobed mixer were analyzed under various welding sequences based on the established finite element model. The results showed that the peak residual stress difference of the lobe mixer is smaller using such a fixture. But different welding sequences affected the stress uniformity throughout the structural member. Only the symmetrical welding of single weld was a better process, with a peak distortion of 0.54 mm and more uniform stress distribution.

New insight into microstructure and mechanical properties of heterostructures 7075 Al joint prepared via single mode laser welding

The application of lightweight and high-strength Al alloys are crucial to reduce energy consumption and emissions in today's world. The lightweight and high strength 7 series aluminum alloy is widely used in aerospace, but its poor welding performance has been a bottleneck restricting the further lightweight of structural parts. In this work, a lightweight and high-strength Al joint with a tensile strength of ∼400 MPa was successfully prepared by single mode laser beam welding using non-weldable 7075 aluminum alloy as the experimental mode. The superfine laser beam reduces the volume of molten pool and increases the solidification rate of molten pool, which significantly inhibits the growth behavior of each microstructure, thus refining the microstructure. The geometrically necessary dislocations (GND) density of each microstructure of 7075 joint after tensile test was: 1.32 × 1014 m−1 for EZ, 1.21 × 1014 m−1 for CLZ, HAZ is 1.17 × 1014 m−1 for HAZ. The synergistic effect of heterogeneous microstructure and work hardening enhanced the tensile strength of 7075 joint. Furthermore, TEM, FIB and EBSD were used to characterize the fracture behavior of the 7075 joint in detail. TEM images showed that the discordant interface between α-Al grain boundary and SiO2 particle was the potential source of crack initiation. The microstructure refinement design and technical selection strategy of the work provide a new insight for laser welding of lightweight and high strength 2xxx/7xxx aluminum alloy.

Numerical and Experimental Analysis of Lap Joints Made of Grade 2 Titanium and Grade 5 Titanium Alloy by Resistance Spot Welding

The paper presents the evaluation of the load capacity of lap joints and the distribution of plastic deformations. The influence of the number and arrangement of welds on the load capacity of the joints and the method of their failure was investigated. The joints were made using resistance spot welding technology (RSW). Two combinations of joined titanium sheets were analyzed: Grade 2-Grade 5 and Grade 5-Grade 5. Non-destructive and destructive tests were carried out in order to verify the correctness of the welds within the given parameters. All types of joints were subjected to a uniaxial tensile test on a tensile testing machine, using digital image correlation and tracking (DIC). The results of the experimental tests of the lap joints were compared with the results of a numerical analysis. The numerical analysis was performed using the ADINA System 9.7.2 and was based on the finite element method (FEM). The conducted tests showed that the initiation of cracks in the lap joints occurred in the place as the maximum plastic deformations. This was determined numerically and confirmed experimentally. The number of welds and their arrangement in the joint affected the load capacity of the joints. Depending on their arrangement, Gr2-Gr5 joints with two welds reached from approximately 149 to 152% of the load capacity of joints with a single weld. The load capacity of the Gr5-Gr5 joints with two welds ranged from approximately 176 to 180% of the load capacity of joints with a single weld. Observations of the microstructure of RSW welds in the joints did not show any defects or cracks. The microhardness test in the Gr2-Gr5 joint showed that the average hardness of the weld nugget decreased by approximately 10-23% when compared to a Grade 5 titanium alloy and increased by approximately 59-92% compared to Grade 2 titanium.

Detection of reinforcement of multi-bead and multi-layer weld in additive manufacturing based on on-line visual information of weld pool

In the multi-bead and multi-layer arc additive manufacturing process, the information of cladding reinforcement reflects the welding quality to a certain extent, so it is of great significance to monitor the reinforcement of cladding layers in real time. In this paper, a point cloud density search method is used to segment the point cloud of a single weld bead in the multi bead weld seam, and then the reinforcement of each cladding bead of multi-bead and multi-layer weld is extracted separately when the bottom plate is deformed due to high temperature, and a residual-based prediction model is constructed for quantitative forecasting of the transient reinforcement before solidification of block cladding layer in real time. The following work is completed to prove the accuracy and effectiveness of the proposed model, two different strategies are used to predict the reinforcement of multi-bead and multi-layer welds. Through the experiment, we can see the mean forecast error of the reinforcement of multi-bead and multi-layer welds is less than 0.3 mm, while the time for the model to dealing with the molten pool image is 18 ms, and the optimal strategy can make the average error better than 0.15 mm, which proves that the model constructed in this paper has great generalization performance and realizes the real-time and high-precision prediction of cladding reinforcement in the case of small deformation. The study of this paper supplies a necessary basis for the online monitoring and control of morphological defects in the process of weld processing.

Fatigue and impact properties of single and double resistance spot welding for high-strength steel used in automotive applications

Fatigue and impact properties of single and double resistance spot welding for high-strength steel used in automotive applications

Explainable Models for Multivariate Time-series Defect Classification of Arc Stud Welding

Arc Stud Welding (ASW) is widely used in many industries such as automotive and shipbuilding and is employed in building and jointing large-scale structures. While defective or imperfect welds rarely occur in production, even a single low-quality stud weld is the reason for scrapping the entire structure, financial loss and wasting time. Preventive machine learning-based solutions can be leveraged to minimize the loss. However, these approaches only provide predictions rather than demonstrating insights for characterizing defects and root cause analysis. In this work, an investigation on defect detection and classification to diagnose the possible leading causes of low-quality defects is proposed. Moreover, an explainable model to describe network predictions is explored. Initially, a dataset of multi-variate time-series of ASW utilizing measurement sensors in an experimental environment is generated. Next, a set of pre-possessing techniques are assessed. Finally, classification models are optimized by Bayesian black-box optimization methods to maximize their performance. Our best approach reaches an F1-score of 0.84 on the test set. Furthermore, an explainable model is employed to provide interpretations on per class feature attention of the model to extract sensor measurement contribution in detecting defects as well as its time attention.

Intermixing behavior of 1.4430 stainless steel and 1.4718 valve steel in in situ alloying using coaxial laser double-wire laser directed energy deposition

Coaxial laser wire directed energy deposition promises a direction-independent buildup of near net shape geometries and surface coatings. Simultaneously introducing two different wire materials into the processing zone enables the production of in situ alloyed or even functionally graded structures. Functionally graded materials and in situ alloyed parts aim to extend the range of materials for development purposes. This work covers the intermixing behavior of two wire materials with greatly differing element contents. Therefore, a multiple diode coaxial laser (DiCoLas) processing head is used consisting of three individually controllable fiber coupled laser diodes with a combined maximum output power of 660 W and a wavelength of 970 nm. Two metal wires, 1.4430 and 1.4718, with a diameter of 0.8 mm are provided simultaneously to the processing zone under an incidence angle of 3.5° to the processing head's middle axis. The DiCoLas processing head enables a stable welding process with good dimensional accuracy of the single welding geometries. Single weld seams and multiple-layer structures are investigated to cover the intermixing behavior for different applications of additive manufacturing. Thermal images of the melting process provide an insight into the melting behavior of the two wire materials and the formation of the weld seam. energy-dispersive x-ray-mappings and line scans display the element distribution of the main alloying elements along the seam cross section. Furthermore, hardness measurements examine the hardness progression along the multiple-layer welding structures showing an even progression of the hardness values over the entire cross section.

Planetary laser welding system induced equiaxed and refined grains in 2A12 aluminum alloy weldments

In this paper, a novel welding technology realized by planetary system laser was proposed. The crystal orientation and growth features in the fusion zones were studied and compared to the result of single laser welding. The single laser welding produced conventional columnar and equiaxed growth of α-Al dendrites in the fusion zone. These two regions both possessed newly nucleated tiny grains and overgrown huge grains. The planetary system laser welding enhanced the free nucleation procedure and promoted the columnar to equiaxed transformation. Compared to a single laser, the average grain misorientation was increased while the aspect ratio and grain size were decreased. Also, the entire orientation distribution exhibited a considerably dispersed fashion. In summary, the planetary system laser welding presented stirring force and disordered heat diffusion during solidification process. The former directly broke up the protuberant tips of trunks and multiplied the number of existing dendrites. The latter reduced the high throughput heat diffusion and produced a relatively low-temperature gradient, thus elevating the supercooling and radial overgrowth of dendrites.

On the connection of the heat input to the forming quality in wire-and-arc additive manufacturing of stainless steels

WAAM (wire-and-arc additive manufacturing) is recently gaining much interest for the fabrication of parts with wide size. A crucial issue associated to this technology is how to control the process variables to achieve expected qualities of parts. The aim of this investigation is to explore the relationship of the heat input (Q) with the forming quality of 308L stainless steel. The outcomes demonstrate that the heat input has significant effects on the shape, microstructures, and mechanical properties of the walls. Both the height and width of single weld beads increase with an increment in Q. The walls fabricated with the low heat inputs feature better mechanical properties and lower surface roughness. The tensile strengths (YS0.2% and UTS) and the surface roughness (Sa) of the walls built with the lower heat input (230 J/mm) are 292 ± 4.95 MPa, 523 ± 4.24 MPa, and 106 μm, respectively, whilst YS0.2% = 273 ± 4.34, UTS = 482 ± 5.66 MPa, and Sa = 179 μm for the wall fabricated with the higher heat input (576 J/mm). This investigation contributes to enriching the understanding on the WAAM process of steels and helping operators to select a proper heat input for specific applications.

Influence of spot welding in adhesive bonded steel sheets on formability and springback

The adhesive bonded steel sheets have main application in the automobile and aircraft manufacturing sectors especially in body-in-white (BIW) applications. Most of the parts in these applications are formed structures. From the literature, it was found that the formability of adhesive bonded sheets is influenced significantly by adhesive properties and interface bonding. Early failure of interface bonding and delamination during deformation of adhesive bonded sheets are major issues that affect the formability. In the present work, the influence of spot welding in adhesive bonded steel sheets on formability issue is investigated. During spot welding of adhesive bonded sheets, location, size and number of weldments were varied at different levels. The weld sizes were in the order of Ø3 mm, Ø5 mm and Ø7 mm. In order to vary the location of weldment, the weld was spotted at 15 mm and 30 mm from the center of gauge region. The number of weld spot was varied like 1, 2 and 3. While varying location and number of weld spots, a constant weld size of Ø7 mm was maintained. Tensile test and V-bending process were carried out. The results like failure pattern, tensile behavior, and elongation were monitored in tensile test. Springback and delamination behavior were evaluated from V-bending process. The results show that there is not much difference in varying size of the weld spots. About 6% increase in elongation is observed with two weld spots at both the extremes of gauge region of the bonded sheets as compared with a single weld at the center. It is understood that deformability of bonded sheets region between two welds increases. In the case of weld location, the weld spot offset at 15 mm shows better elongation than the weld at center and offset at 30 mm. From the results, spotting weld at an appropriate location slightly away from the gauge region improves the elongation of bonded steel sheets, a reduction in springback and eliminated delamination are observed with spot welding of adhesive bonded steel sheets and concludes that the spot welds in the adhesive bonded steel sheets arrest the relative motion between two base materials, and influences the overall formability. The results of the present study could be useful in controlling early failure, formability, springback and delamination of adhesive bonded steel sheets.

Uticaja parametara režima hibridnog laserskog elektrolučnog zavarivanje konstrukcijskih čelika - pregled stanja

The effectiveness of the hybrid laser arc welding is based on the combination of two heat sources in a single welding process, resulting in welding process that is characterized with higher welding speed, increased productivity, deeper penetration, stable process, better gap bridging ability, less heat input to the welding material and high flexibility. The physical complexity of the process is a main disadvantage, i.e. an increased number of parameters that need to be synchronized and optimized in order to obtain a perfect weld. In this paper, based on the previous experimental research, a complete analysis of the primary hybrid laser arc welding parameters was performed, and general conclusions were drawn regarding their impact on the welding process stability, the weld shape and its mechanical characteristics. The introduction part contains a general analysis of previous research. In the second part, characteristics of the performed hybrid welds in structural steels and detailed analysis are presented. In the final part, general conclusions are made regarding the influence of the primary hybrid laser arc welding parameters on the structural steel.

Design and Test of Duckbill Welding Robot for Cotton Seeder

To improve the automation, welding efficiency, and welding quality of duckbill welding of the cotton seeder, this study designed a cotton seeder duckbill welding robot. According to the characteristics of the duckbill weldment and welding requirements, the overall structure of the welding robot was determined, including the girdle feeding mechanism, static duckbill feeding mechanism, hinge feeding mechanism, welding fixture, welding actuator, and control system. To realize the continuous automatic feeding, positioning, fixing, welding, and unloading of the workpiece in the duckbill welding, the feeding mechanism adopts the method of cooperative cooperation of inductive proximity switch, electromagnet, and cylinder. The main body of the welding fixture adopts the pneumatic clamping method; the welding actuator adopts the synchronous belt module electric drive so that the welding torch can move in a straight line along the X axis and the Z axis. The welding process of the duckbill was simulated by Simufact Welding software, and the deformation and stress changes of the weldment were compared and analyzed when the single-sided single welding, the bilateral symmetrical double welding torch, two welding forms, and two welding process parameters were used to determine the welding process parameters of the welding robot. The prototype was made and the welding test was carried out. The test results show that the duckbill welding robot of the cotton seeder has stable feeding, solid clamping, accurate positioning, and high welding efficiency. According to the national standard, the appearance of the duckbill weld is inspected. The surface of the duckbill weld and the heat-affected zone has no cracks, incomplete fusion, slag inclusion, crater, and porosity. The forming quality of the welded parts is good. The design of the duckbill welding robot for cotton seeder is helpful in solving the problems of cumbersome positioning and clamping and low efficiency in manual and semi-automatic duckbill welding robots, which provides a strong guarantee for the large-scale and standardized welding production of the dibbler duckbill.

Stability enhancement of molten pool and keyhole for 2195 Al[sbnd]Li alloy using fiber-diode laser hybrid welding

Molten pool and keyhole stability are vital concerns in laser welding of 2195 AlLi alloy, potentially affecting the weld quality and porosity defect. Fiber-diode laser hybrid welding, which coaxially superimposes dual laser beams with different wavelengths and spot diameters, is superior in improving welding stability and quality. In this paper, the molten pool dynamic characteristics associated with the keyhole during fiber-diode laser hybrid welding were innovatively investigated to explore the impact of different laser energy on welding stability. The inner keyhole was observed by utilizing the “sandwich” structure with 2195 AlLi alloy and refractory glass. The experimental results indicate that during fiber-diode laser hybrid welding, a larger molten pool and plasma plume, deeper keyhole depth, and smoother keyhole rear wall are generated compared to single fiber laser welding. It is shown that the closing of the keyhole entrance and the swelling of the molten pool are effectively inhibited due to the superposition of the diode laser. The average keyhole depth during fiber-diode laser hybrid welding at the PD of 2500 W is substantially increased compared to that during single fiber laser welding. Based on the keyhole and molten pool characteristics, the mechanism of stability enhancement with the assistance of a diode laser is understood. In addition, the fiber-diode hybrid welding method can achieve a weld seam (WS) with high-quality surface morphology and a low porosity ratio of 0.7 %. This work provides the necessary theoretical basis and technical guidance for the fiber-diode laser hybrid welding technology of aluminum alloy.

Effect on Various Parameter of Stainless Steel 316L Weld Bead Geometry using Cold Metal Transfer (CMT) Process

This study influences the effect of various process parameters on Cold Metal Transfer (CMT) of stainless steel 316L using mild steel as substrate. CMT has a benefit of a minimal heat input, a high deposition rate, and increased efficiency. Typically, single pass weld beads are utilized for repair and remanufacturing. The geometry of the beads determines the cladding performance of additively produced components. Therefore, optimal range of bead characteristics is necessary to ensure superior mechanical qualities. The parameters includes as: welding current, travel speed and feed speed, were tuned to produce joints with complete penetration depth and zero defects. The weld bead with lower wire travel speed of (2.9 m/min) and higher wire feed speed of (4.9 m/min) at current value of (141A) shows the optimum value of (bead width: 3.56 mm, bead height: 1.72mm, weld penetration: 3.83mm and dilution: 1.5%). This was attributed to the decreases of wire travel speed and increases of wire feed speed ensuring better penetration and larger molten metal. While a higher current value causes the convexity area of the bead to rise, it displays a stronger penetration and minimal dilution.