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<p>Wire Arc Additive Manufacturing (WAAM) of S355 steel is strongly influenced by the interaction between arc mode and build geometry, which governs thermal history and microstructural evolution. This study investigates thin (5&#xa0;mm) and thick (25&#xa0;mm) walls produced using Pulse-MIG and CMT processes through multi-scale characterization and energy-based analysis. Results show a transition from refined, homogeneous microstructures in thin walls to coarser, thermally heterogeneous structures in thick walls due to cumulative thermal cycling. This evolution leads to an increase in hardness of ~ 10–15 HV, with Pulse-MIG consistently exhibiting higher hardness than CMT (≈ 5–10 HV difference). The observed hardness ranking is interpreted using line energy and volumetric energy density as comparative process descriptors, while recognizing that the complete thermal response also depends on interpass control, heat dissipation, bead geometry, and cumulative reheating. Under the investigated conditions, wall geometry formed part of the effective thermal-control system by modifying the deposited material volume and heat-dissipation conditions. The proposed approach should therefore be regarded as a physics-informed comparative framework for WAAM-fabricated S355 steel rather than as a universal predictive model. The key finding is that wall geometry acts as a thermal control parameter, directly influencing microstructure–property relationships. This work provides a physics-based framework for optimizing WAAM process parameters and improving the performance of structural steel components.</p>

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Optimization of electric arc parameters for structural changes in parts obtained using WAAM technology

  • 期刊论文

  • 发表日期：

    2026年6月24日

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  • Elvira Chukenova,
  • Erik Nugman,
  • Bekmambet Kanagat,
  • Baibatsha Akerke Kentaikyzy,
  • Azamat Mustafa,
  • Karpov Alexander,
  • Matias Jaskari,
  • Antti Jarvenpaa,
  • Omar Khatir,
  • Atef S. Hamada

摘要

Wire Arc Additive Manufacturing (WAAM) of S355 steel is strongly influenced by the interaction between arc mode and build geometry, which governs thermal history and microstructural evolution. This study investigates thin (5 mm) and thick (25 mm) walls produced using Pulse-MIG and CMT processes through multi-scale characterization and energy-based analysis. Results show a transition from refined, homogeneous microstructures in thin walls to coarser, thermally heterogeneous structures in thick walls due to cumulative thermal cycling. This evolution leads to an increase in hardness of ~ 10–15 HV, with Pulse-MIG consistently exhibiting higher hardness than CMT (≈ 5–10 HV difference). The observed hardness ranking is interpreted using line energy and volumetric energy density as comparative process descriptors, while recognizing that the complete thermal response also depends on interpass control, heat dissipation, bead geometry, and cumulative reheating. Under the investigated conditions, wall geometry formed part of the effective thermal-control system by modifying the deposited material volume and heat-dissipation conditions. The proposed approach should therefore be regarded as a physics-informed comparative framework for WAAM-fabricated S355 steel rather than as a universal predictive model. The key finding is that wall geometry acts as a thermal control parameter, directly influencing microstructure–property relationships. This work provides a physics-based framework for optimizing WAAM process parameters and improving the performance of structural steel components.