Strength Characteristics Prediction of the Metal Obtained by Wire Arc Additive Manufacturing

The mechanical properties of metals produced by Wire Arc Additive Manufacturing (WAAM) differ significantly from those of rolled sheets due to their cast-like structure and repeated thermal cycling. This study aims to develop a predictive model capable of accurately estimating the stress–strain behavior of deposited metal based on process parameters. To achieve this, a series of experiments were conducted, and test specimens were produced. Arc current and deposition rate were selected as factors in a quasi-D-optimal experimental design. Tensile test data were analyzed using the least squares method, resulting in the derivation of regression equations that relate the stress–strain characteristics to the deposition parameters. To verify that the location of specimen extraction does not influence the test results, both thermal modeling and metallographic analysis were employed. Three key findings were established: (1) Thermal simulations and metallographic observations indicate that after the deposition of the first 5–6 layers, the microstructure becomes relatively similar; (2) significant microstructural variation occurs only in the final layer; and (3) six new regression equations were developed to predict the mechanical properties of the deposited metal based on WAAM process parameters.