Exploring the hybridization of wire-arc additive manufacturing and resistance spot welding

This paper explores a new hybrid manufacturing approach that combines wire-arc additive manufacturing (WAAM) with resistance spot welding (RSW). The approach integrates additively deposited materials with commercial sheets, which can serve as either supporting or functional elements. Experimental testing and finite element modelling allowed defining the weld lobe and optimizing key parameters such as electric current and welding time. Optimization was based on nugget shape, microstructure, and mechanical performance from destructive shear and peel tests. Two distinct joining modes were identified: symmetric and asymmetric weld nuggets, with the former exhibiting higher strength but requiring a higher heat input. A proof-of-concept prototype was developed to demonstrate the potential of this innovative hybrid manufacturing approach, combining WAAM, machining, forming, and RSW to fabricate complex, multi-thickness components with improved structural integrity.