The influence of welding modes on metallic structures processed through WAAM

Abstract Wire arc additive manufacturing (WAAM) has emerged as a versatile and cost-effective technique for fabricating complex, large-scale components with enhanced material flexibility. The bead profile, like width, height, and penetration, is critical in WAAM fabrication, influencing the quality and performance of the final component. Consistent and precise profiles are essential for accurate layering and material deposition in complex 3D structures. Various parameters, such as current, voltage, deposition rate, interpass temperature, and welding mode, impact deposit quality in WAAM. This study focuses on implementing a controlled heat input deposition approach, utilizing various welding modes: Control Weld (classic MIG/MAG), Speed Weld (voltage-controlled pulsed arc), Vari Weld (current-controlled pulsed arc), Rapid Weld (high-capacity spray arc), Root Weld (energy-reduced short arc), and Fine Weld (energy-reduced, current-controlled short arc). The study scrutinizes the impact of altering the welding mode on bead profile, bead quality, macroscopic morphology, microstructure, and mechanical properties in single-bead WAAM structures.