Analysis of Parameters Based on Deposited Beads Geometry in Single-Pass Multi-layers Applied in Wire Arc Additive Manufacturing Process

This study aims to provide insight to assist in decision-making in wire arc additive manufacturing based on the prediction of bead geometry, which is affected by the behavior of the melt pool. This requires the identification of welding techniques that can minimize the material transfer rate, minimize the effects caused in the lower layers, and reduce the volume of the molten pool material. It was also found there exists a minimum deposition volume such that the beads remain stable. Therefore, in this study, the behavior of the weld beads was verified as a function of the volume of metal deposited over the welded length by systematically varying the mean current and the pulse frequency in GMAW-P. In addition, the prediction of weld bead geometry decreases the possibility of error, avoiding material waste. Thus, the influences of each welding parameter (voltage, current, and welding speed) on the dimensional characteristics of the beads (width and reinforcement) were analyzed. The analysis results allowed formulation of the relationships among the bead features and the welding parameters. Additionally, it was verified that the deposition rate is directly affected by the stick-out and inversely proportional to the arc voltage. The modeling of the weld bead geometry as a function of the welding parameters will enhance the quality of automated welding, allowing early simulation and achieving an efficient process. The modeling of the weld bead geometry using the linear regression technique will allow manipulation of the welding process variables based on the necessary bead characteristics.