The influence of the wire and arc additive manufacturing parameters on the surface irregularities

Wire and arc additive manufacturing (WAAM) has been demonstrated to be a pioneering process for producing small- to large-scale components with its high deposition rate and flexible deposition capability. However, WAAM has critical drawbacks, including pronounced surface irregularities and the need for secondary machining operations. The presence of surface irregularities also negatively affects the surface flatness/waviness of the as-built part and the effective wall width and height after machining. To enhance surface properties, examining the impact of WAAM parameters is necessary. As a result, this study explores the impact of wire feed speed (WFS) and traveling speed parameters on single-material WAAMed samples made of stainless steel 309L. The study examined surface irregularities such as flatness, distortion, and effective wall thickness using detailed three-dimensional scanning techniques. Hardness measurements were also conducted to evaluate hardness distribution along the deposition direction. The analysis focused on the interaction between WAAM process parameters and surface irregularities. The results indicate that the heat input is the most influential deposition criterion affecting surface irregularities, such as flatness and distortion. These findings contribute to a deeper understanding of the complex interplay of deposition parameters, providing valuable information for optimizing the WAAM processes. In conclusion, this study offers insights into the intricate dynamics of WAAM. It highlights the crucial role of WFS, travel speed, and heat input in shaping surface properties.