Investigating the layer-wise arc and melt-pool characteristics of near-substrate wire arc-directed energy deposited NiCrMo-3 alloy using image processing

This article uses an in situ image processing technique to investigate the intricate relationship between various process parameters and the number of layers deposited in the context of arc and melt-pool characteristics. Through a systematic analysis, the study uncovers the significance of travel speed (TS), mean current ( I m ), and layer numbers (LN) in shaping these characteristics. The results reveal that while higher TS corresponds to increased arc length ( L A ) at lower I m , this correlation diminishes with rising LN. Conversely, lower TS leads to an opposite trend, where L A rises with LN at lower I m . The arc deflection angle ( A D ) consistently increases with LN, influenced by both I m and TS. Notably, higher molten pool penetration ( D M ) is achieved with higher TS and lower I m , and D M gradually decreases as LN increases. The interplay between L A , heat input ( H I ), and L M displays a nuanced pattern, with H I influencing L A and L M differently. The study introduces ratios such as L A / D M and L A / L M , indicating their dependency on TS, I m , and LN. A significant insight arises from successfully implementing quadratic polynomial models, demonstrating strong predictive capabilities for various characteristics. These models exhibit exceptional accuracy when validated against empirical measurements, showcasing their effectiveness in forecasting arc and melt-pool behaviors, thereby emphasizing the intricate nature of the deposition process.