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<p>To predict single-bead geometry, a multi-response mathematical model is created using design expert software. This model looks at how changes in input factors, such as travel speed and current, affect output responses, such as weld width, weld reinforcement, penetration depth, contact angle, and dilution, because these factors have a significant impact on aesthetics and properties. The goal is to optimize these input factors for the fabrication of high-quality wire arc additive manufactured (WAAM) single and multi-wall structures with a cold metal transfer (CMT) heat source for use in naval guns in defense. Response surface methodology (RSM) and central composite face-centered design (CCFCD) were used to create a design matrix for the experiment. WAAM single-wall structures, a novel work, served as the basis for the response criteria used to optimize the process parameters. The output responses of the manufactured beads were examined using ImageJ software. The results show that weld reinforcement height is less impacted by variations in heat input value than weld width and penetration depth. Weld width and penetration depth reached their maximum values at the highest heat input with the highest current (100 A) and the lowest travel speed (4&#xa0;mm/s), whereas the maximum value of weld reinforcement was reached at the lowest current (60 A) and the lowest travel speed (4&#xa0;mm/s). The ideal input process parameters for a high-quality WAAM structure and a visually appealing WAAM bead are (4.49209) mm/s for travel speed and (80.6628) A for current, with a heat input of (182.44) J/mm.</p>

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Multi-response Process Parameter Optimization of Weld Bead Using Central Composite Face-Centered Design for Fabrication of Good-Quality Wire Arc Additive Manufactured Single Wall Structures

  • 期刊论文

  • 发表日期：

    2026年1月12日

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  • Faim Khan,
  • Yashwant Koli,
  • Mukesh Kumar,
  • Jinesh Kumar Jain

摘要

To predict single-bead geometry, a multi-response mathematical model is created using design expert software. This model looks at how changes in input factors, such as travel speed and current, affect output responses, such as weld width, weld reinforcement, penetration depth, contact angle, and dilution, because these factors have a significant impact on aesthetics and properties. The goal is to optimize these input factors for the fabrication of high-quality wire arc additive manufactured (WAAM) single and multi-wall structures with a cold metal transfer (CMT) heat source for use in naval guns in defense. Response surface methodology (RSM) and central composite face-centered design (CCFCD) were used to create a design matrix for the experiment. WAAM single-wall structures, a novel work, served as the basis for the response criteria used to optimize the process parameters. The output responses of the manufactured beads were examined using ImageJ software. The results show that weld reinforcement height is less impacted by variations in heat input value than weld width and penetration depth. Weld width and penetration depth reached their maximum values at the highest heat input with the highest current (100 A) and the lowest travel speed (4 mm/s), whereas the maximum value of weld reinforcement was reached at the lowest current (60 A) and the lowest travel speed (4 mm/s). The ideal input process parameters for a high-quality WAAM structure and a visually appealing WAAM bead are (4.49209) mm/s for travel speed and (80.6628) A for current, with a heat input of (182.44) J/mm.