Optimization of Welding Parameters to Prevent Angular Distortion of Mild Steel Wire Arc Additive Manufacturing Parts

Doğan E., Ay M., Kurtulmuş M.

JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE, 2025 (SCI-Expanded, Scopus) identifier identifier

  • Yayın Türü: Makale / Tam Makale
  • Basım Tarihi: 2025
  • Doi Numarası: 10.1007/s11665-025-11905-z
  • Dergi Adı: JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE
  • Derginin Tarandığı İndeksler: Science Citation Index Expanded (SCI-EXPANDED), Scopus, PASCAL, Aerospace Database, Applied Science & Technology Source, Aquatic Science & Fisheries Abstracts (ASFA), Chemical Abstracts Core, Communication Abstracts, Compendex, Computer & Applied Sciences, INSPEC, Metadex, Civil Engineering Abstracts
  • Anahtar Kelimeler: angular distortion, distortion of WAAM parts, GMAW primary welding parameters, Taguchi method, welding residual stresses, wire arc additive manufacturing
  • Marmara Üniversitesi Adresli: Evet

Özet

Wire arc additive manufacturing (WAAM) is a specialized form of metal additive manufacturing that utilizes automated welding techniques. In essence, the process relies on electric arc energy to incrementally deposit layers of molten metal, thereby constructing medium to large-scale metallic structures. This approach effectively merges traditional welding technology with modern automation to enable the efficient production of sizable metal components. During WAAM part production, thermal stresses form because of uneven heating and cooling. These stresses cause angular and bending distortions. Residual stress and distortion adversely affect the serviceability of the workpiece. In this investigation, the wire arc additive manufacturing (WAAM) process was employed, utilizing EN ISO 14341-A:G 38 2 C1 Z 3Si1 solid wire with EN 10250-2:S235JRG2 mild steel substrates. The primary objective was to systematically evaluate how different welding parameters impact the angular distortion present in the resulting WAAM components. Wire feed rate and arc voltage increased the distortion. The distortion decreased with the welding speed. Optimization of primary welding parameters for minimum angular distortion was achieved by Taguchi method. This study addresses a gap in the literature by offering a comprehensive approach focused on angular distortion control in wire arc additive manufacturing. Supported by experiments and optimized using the Taguchi method, it sheds light on the impact of parameters on distortion. The analysis enhances existing knowledge and guides future research endeavors.