Skip to main content
SpringerLink
Log in

Effects of weave path parameters on the geometry of wire arc additive manufactured features

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

The present work investigates the effect of process parameters on the geometry of wire arc additive manufactured parts. The geometric accuracy of features produced with a weaving strategy is compared to what can be accomplished with a typical overlapping bead strategy. In this work, single-layer and multi-layer geometries were deposited under varying process and path parameters. The wavelength, amplitude, and torch speed of the weaving path were varied, while the power, wire feed speed, and contact tip to work distance remained constant. The geometric deposition efficiencies of several samples produced with a weave strategy are directly compared to samples generated with two parallel overlapping beads with torch speeds defined to match the deposition rate of the weave samples. Feature geometries were characterized using optical microscopy and laser scanning data. The results indicate that implementing a weave path strategy can improve the geometric accuracy of wire arc additive features, thus increasing the effective volumetric deposition rate of the process. It is shown that the most consistent improvements resulted from the combination of low wavelength and high amplitude, which correlate to wider and taller printed layers.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19

Similar content being viewed by others

Data Availability

All data is available upon request to the corresponding author

References

  1. Williams SW, Martina F, Addison AC, et al. (2016) Wire + arc additive manufacturing. Mater Sci Technol 32(7):641–647. https://doi.org/10.1179/1743284715Y.0000000073

    Article  Google Scholar 

  2. Ding D, Pan Z, Cuiuri D, et al. (2015) Wire-feed additive manufacturing of metal components: technologies, developments and future interests. Int J Adv Manuf Technol 81(1):465–481. https://doi.org/10.1007/s00170-015-7077-3

    Article  Google Scholar 

  3. Yang D, Wang G, Zhang G (2017) Thermal analysis for single-pass multi-layer GMAW based additive manufacturing using infrared thermography. J Mater Process Technol 244:215–224. https://doi.org/10.1016/j.jmatprotec.2017.01.024

    Article  Google Scholar 

  4. Colegrove PA, Coules HE, Fairman J, et al. (2013) Microstructure and residual stress improvement in wire and arc additively manufactured parts through high-pressure rolling. J Mater Process Technol 213 (10):1782–1791. https://doi.org/10.1016/j.jmatprotec.2013.04.012

    Article  Google Scholar 

  5. Fuchs C, Baier D, Semm T, et al. (2020) Determining the machining allowance for WAAM parts. Prod Eng 14(5):629–637. https://doi.org/10.1007/s11740-020-00982-9

    Article  Google Scholar 

  6. Jafari D, Vaneker THJ, Gibson I (2021) Wire and arc additive manufacturing: Opportunities and challenges to control the quality and accuracy of manufactured parts. Mater Des 202:109,471. https://doi.org/10.1016/j.matdes.2021.109471

    Article  Google Scholar 

  7. Hu JF, Yang JG, Fang HY, et al. (2006) Numerical simulation on temperature and stress fields of welding with weaving. Sci Technol Weld Join 11(3):358–365. https://doi.org/10.1179/174329306X124189

    Article  Google Scholar 

  8. Chen Y, He Y, Chen H, et al. (2014) Effect of weave frequency and amplitude on temperature field in weaving welding process. The Int J Adv Manuf Technol 75(5-8):803–813. https://doi.org/10.1007/s00170-014-6157-0

    Article  Google Scholar 

  9. He T, Yu S, Runzhen Y et al (2022) Oscillating wire arc additive manufacture of rocket motor bimetallic conical shell. The International Journal of Advanced Manufacturing Technology https://doi.org/10.1007/s00170-021-08477-2

  10. Yaseer A, Chen H (2021) Machine learning based layer roughness modeling in robotic additive manufacturing. J Manuf Process 70:543–552. https://doi.org/10.1016/j.jmapro.2021.08.056

    Article  Google Scholar 

  11. Ma G, Zhao G, Li Z, et al. (2019a) A path planning method for robotic wire and arc additive manufacturing of thin-Walled structures with varying thickness. IOP Conf Series: Mater Sci Eng 470:012,018. https://doi.org/10.1088/1757-899X/470/1/012018

    Article  Google Scholar 

  12. Ma G, Zhao G, Li Z, et al. (2019b) Optimization strategies for robotic additive and subtractive manufacturing of large and high thin-walled aluminum structures. Int J Adv Manuf Technol 101 (5-8):1275–1292. https://doi.org/10.1007/s00170-018-3009-3

    Article  Google Scholar 

  13. Zhan X, Zhang D, Liu X, et al. (2017a) Comparison between weave bead welding and multi-layer multi-pass welding for thick plate Invar steel. Int J Adv Manuf Technol 88(5):2211–2225. https://doi.org/10.1007/s00170-016-8926-4

    Article  Google Scholar 

  14. Zhan X, Liu X, Wei Y, et al. (2017b) Microstructure and property characteristics of thick Invar alloy plate joints using weave bead welding. J Mater Process Technol 244:97–105. https://doi.org/10.1016/j.jmatprotec.2017.01.014

    Article  Google Scholar 

  15. Guzman-Flores I, Vargas-Arista B, Gasca-Dominguez JJ, et al. (2017) Effect of torch weaving on the microstructure, tensile and impact resistances, and fracture of the HAZ and weld bead by robotic GMAW process on ASTM a36 steel. Soldagem & Inspeç,ão 22:72–86. https://doi.org/10.1590/0104-9224/SI2201.08

    Article  Google Scholar 

  16. Aldalur E, Veiga F, Suárez A, et al. (2020a) Analysis of the wall geometry with different strategies for high deposition wire arc additive manufacturing of mild steel. Metals 10(7):892. https://doi.org/10.3390/met10070892

    Article  Google Scholar 

  17. Aldalur E, Veiga F, Suárez A, et al. (2020b) High deposition wire arc additive manufacturing of mild steel: Strategies and heat input effect on microstructure and mechanical properties. J Manuf Process 58:615–626. https://doi.org/10.1016/j.jmapro.2020.08.060

    Article  Google Scholar 

  18. Ding D, Pan Z, Cuiuri D, et al. (2015) A multi-bead overlapping model for robotic wire and arc additive manufacturing (WAAM). Robot Comput Integr Manuf 31:101–110. https://doi.org/10.1016/j.rcim.2014.08.008

    Article  Google Scholar 

  19. Rao PS, Gupta OP, Murty SSN (2004) A study on the weld bead characteristics in pulsed gas metal arc welding with rotating arc. In: 23rd International Conference on Offshore Mechanics and Arctic Engineering, Volume 2. ASMEDC, pp 953–957 https://doi.org/10.1115/OMAE2004-51580

  20. Cai C, Li L, Chen X, et al. (2016) Study on laser-MAG hybrid weaving welding characteristics for high-strength steel. J Laser Appl 28(2):022,401. https://doi.org/10.2351/1.4944095

    Article  Google Scholar 

  21. Karadeniz E, Ozsarac U, Yildiz C (2007) The effect of process parameters on penetration in gas metal arc welding processes. Mater Des 28(2):649–656. https://doi.org/10.1016/j.matdes.2005.07.014

    Article  Google Scholar 

Download references

Acknowledgements

Thank you to Jaime Berez (Georgia Institute of Technology) for providing self-developed MATLAB tools that aided in the metrology and analysis portion of this research.

Funding

This work was supported by the US Department of Energy DE-EE0008303

Author information

Authors and Affiliations

  1. George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA, USA

    Jacob Bultman & Christopher Saldaña

Authors
  1. Jacob Bultman
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Christopher Saldaña
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Conceptualization: Jacob Bultman, Christopher Saldana. Methodology: Jacob Bultman. Validation: Jacob Bultman, Christopher Saldana. Analysis: Jacob Bultman. Writing — original draft: Jacob Bultman. Writing — review and editing: Christopher Saldana. Funding acquisition: Christopher Saldana. All authors have read and agreed to the published version of the manuscript.

Corresponding author

Correspondence to Jacob Bultman.

Ethics declarations

Conflict of interest

The authors declare no competing interests

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Bultman, J., Saldaña, C. Effects of weave path parameters on the geometry of wire arc additive manufactured features. Int J Adv Manuf Technol 124, 2563–2577 (2023). https://doi.org/10.1007/s00170-022-10546-z

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-022-10546-z

Keywords

Search

Navigation