Mechanistic Insights into Spatially Resolved Molten Pool Dynamics and Energy Coupling in CMT-WAAM of 316L Stainless Steel

This study investigated the influence of spatial orientation on bead morphology and molten pool dynamics during cold metal transfer wire arc additive manufacturing (CMT-WAAM). Experiments in horizontal, transverse, vertical-down, and vertical-up orientations under varying wire feed speeds revealed that increasing the feed rate improved bead uniformity and reduced defects in horizontal deposition, while gravity-induced asymmetry dominated non-horizontal orientations. Transverse cladding produced tilted, uneven beads with reduced penetration; vertical-down enhanced lateral spreading but resulted in the shallowest weld depth; vertical-up limited spreading, yielding narrow beads with higher reinforcement. Optimal cladding quality was achieved at a wire feed speed of 6.7 m/min for the first layer, with a reduced heat input applied for subsequent layers to minimize residual stress and deformation. Numerical simulations further elucidated transient temperature and flow fields. Heat accumulation and dissipation varied with orientation and layer sequence: horizontal deposition formed deep, symmetric pools; transverse deposition generated asymmetric vortices and uneven solidification; vertical-up deposition caused upward counterflow with restricted spreading; vertical-down promoted rapid spreading and faster solidification. A detailed comparison between simulated and experimental temperature distributions and cross-sectional profiles demonstrated excellent agreement, thereby validating the accuracy and predictive capability of the developed model. This integrated experimental-numerical approach provided a comprehensive understanding of orientation-dependent molten pool behavior and offered a robust framework for optimizing process parameters, enhancing dimensional accuracy, and controlling defects in CMT additive manufacturing.