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<p>Compared to other metallic additive manufacturing methods, wire arc additive manufacturing (WAAM) has a number of benefits, such as more material composition flexibility and less equipment expenses. Improving material quality, decreasing faults, increasing production, and lowering expenses all depend on streamlining the WAAM process. However, difficulties like uneven welding, irregular feed rates, and the wrong torch angle can lead to problems including humping, oxidation, and pore growth. By adjusting the torch angle in combination with welding speed and feed rates, the study seeks to reduce the void radius and enhance the wear resistance and elastic modulus of WAAM Al5356 walls. The parametric study identifies the optimal conditions, and the findings demonstrate how crucial torch angle is in reducing void formation. Confirmation testing showed that reducing the void radius to 40.5&#xa0;µm increased the wear resistance by 74.7% and the elastic modulus by 56.3% when using a 90° torch angle with a feed speed of 7&#xa0;m/min and a moving speed of 55&#xa0;cm/min. Elastic modulus mapping provided additional confirmation of the ideal values, and worn-out surface analysis clarified the wear process associated with voids. These adjusted parameters hold promise for high-quality, high-performance components that meet stringent industrial standards.</p>

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Role of torch angle in dry sliding wear performance of Al5356 walls produced by wire arc additive manufacturing process

  • 期刊论文

  • 发表日期：

    2025年4月3日

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  • Saravana Kumar Murugesan,
  • Jeyaprakash Natarajan,
  • Che-Hua Yang

摘要

Compared to other metallic additive manufacturing methods, wire arc additive manufacturing (WAAM) has a number of benefits, such as more material composition flexibility and less equipment expenses. Improving material quality, decreasing faults, increasing production, and lowering expenses all depend on streamlining the WAAM process. However, difficulties like uneven welding, irregular feed rates, and the wrong torch angle can lead to problems including humping, oxidation, and pore growth. By adjusting the torch angle in combination with welding speed and feed rates, the study seeks to reduce the void radius and enhance the wear resistance and elastic modulus of WAAM Al5356 walls. The parametric study identifies the optimal conditions, and the findings demonstrate how crucial torch angle is in reducing void formation. Confirmation testing showed that reducing the void radius to 40.5 µm increased the wear resistance by 74.7% and the elastic modulus by 56.3% when using a 90° torch angle with a feed speed of 7 m/min and a moving speed of 55 cm/min. Elastic modulus mapping provided additional confirmation of the ideal values, and worn-out surface analysis clarified the wear process associated with voids. These adjusted parameters hold promise for high-quality, high-performance components that meet stringent industrial standards.