Experimental investigations on Wall Geometry and Waviness

Additive manufacturing by direct energy deposition, particularly through the CMT-WAAM (Cold Metal Transfer-Wire Arc Additive Manufacturing) process, is an innovative production technique that is growing interest due to its ability to produce complex metal parts with high efficiency and flexibility. Additionally, this technology allows the use of a wide range of materials and alloys, such as SS308L stainless steel (the focus of our study), which is known for its excellent mechanical properties and corrosion resistance, which making it a preferred choice for various industrial applications, including the medical, aerospace and food sectors. However, for this technology to be profitable and productive, it is important to optimize its manufacturing parameters to obtain parts with optimal geometric and mechanical properties. One of the key challenges in CMT-WAAM manufacturing is achieving precise control over the geometry of the weld bead and ensuring uniformity across deposited layers. The function of parts manufactured using additive manufacturing is highly sensitive to process parameters variations, which impact surface finish, dimensional tolerances, and mechanical properties. The study focuses on the weld bead geometry and surface waviness of SS308L stainless steel parts manufactured using the CMT-WAAM process. The welding parameters (wire feed rate, travel speed, and interlayer time) were studied to identify their influence on the weld bead geometry and wall surface undulation. Based on the analysis of results, this study seeks to provide useful guidelines for adjustment of process conditions to improve the quality and integrity of CMT-WAAM parts and encourage wider industrial application of this technique.