Effect of process parameters on mechanical properties of 5554 aluminum alloy fabricated by wire arc additive manufacturing

Abstract Wire and arc additive manufacturing (WAAM) represents an additive manufacturing process utilizing an electric arc to liquefy wire feedstock, enabling the precise deposition of material layers to construct intricate structures. The advantages of high product quality and fast production make the WAAM method stand out. This study delves into the critical role of process parameter optimization in WAAM, focusing on the application of 5554 aluminum wire as a suitable material. Through analysis of samples produced with parameters including robot speed, wire feeding speed, and dwell time between layers, the study aims to elucidate their impact on final product characteristics. By assessing different values for each parameter and employing six distinct parameter sets in sample manufacturing, the research facilitates comprehensive comparative analysis. Mechanical testing of the produced samples reveals a significant correlation between heat input during aluminum alloy production and resulting hardness values, underscoring the pivotal role of temperature control in process. The highest properties were at the wire feed speed 7.5 m min −1 , robot speed 0.5 m min −1 and dwell time between layers 30 s. These findings not only highlight the importance of meticulous parameter selection in WAAM but also contribute valuable insights for optimizing production processes and enhancing material properties.