Fine-tuning of interlayer time interval in WAAM process to enhance the wear resistance of Al5356 walls

Abstract Wire Arc Additive Manufacturing (WAAM) offers several advantages over other metallic additive manufacturing techniques, including greater flexibility in material composition and lower equipment costs. Optimizing the WAAM process is critical to enhancing material quality, minimizing defects, boosting production efficiency, and reducing costs. Challenges such as uneven deposition speed, inconsistent material flow, and inadequate interlayer time intervals can result in defects like humping, oxidation, and porosity. This study focuses on optimizing interlayer time intervals in conjunction with deposition speed and material deposition rates to minimize porosity and improve the wear resistance and nano-hardness of WAAM-fabricated Al5356 walls. This research used the Weighted Aggregated Sum Product Assessment (WASPAS) method to identify the optimal process parameters. It revealed that porosity was reduced to 0.06% by setting the interlayer time gap to 120 s, the deposition speed to 75 cm min −1 , and the material deposition rate to 4 m min −1 . This reduction increased wear resistance by 76% and nano-hardness by 87%. Nano-hardness mapping validated these optimal settings, and surface analysis of worn samples provided insights into the relationship between porosity and wear behavior. These optimized parameters allow for the manufacturing of wear-resistant components, such as landing gear parts, for the aerospace industry.