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<p>Wire arc additive manufacturing (WAAM) offers significant advantages for the fabrication of stainless-steel components; yet, the optimization of process parameters remains critical for achieving desirable geometric and microstructural properties. This study investigates the effects of travel speed, welding current, and wire feed ratio on the layer geometry and microstructure of SS309L stainless steel produced via robotic double-wire MIG welding. Using a Taguchi L9 orthogonal array, the main and interaction effects of these parameters were systematically evaluated. Analysis of variance revealed that wire feed ratio is the most influential factor, contributing (43.6%) to wall height variation, followed by travel speed (22.3%) and welding current (15.9%). A linear regression model was developed to predict wall height, achieving strong agreement with experimental results, with a maximum wall height of 30.79&#xa0;mm and a deviation below 2.5%. Microstructural analysis showed that the incorporation of cold wire feeding promotes the formation of vertically aligned dendritic structures and a refined granular matrix, resulting in dense, defect-free deposits. In contrast, specimens produced without cold wire feeding exhibited coarser dendritic features and less uniform morphology. These improvements in microstructure are directly associated with enhanced surface quality and mechanical integrity of the additively manufactured walls. The results provide valuable guidance for tailoring WAAM process parameters to achieve precise geometries and consistent material properties in stainless-steel components, thereby informing continuous optimization efforts.</p>

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Effect of Double-Wire Cold Feeding on Wire Arc Additive Manufacturing of SS309L Layer Geometry

  • 期刊论文

  • 发表日期：

    2026年5月16日

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  • Hassan J. Khaudair,
  • Adnan A. Ugla,
  • Hadeer Alshihmani,
  • Yousri A. Baji,
  • Ali K. AbdulRazzaq,
  • Rania Ali,
  • Haneen Hameed Hlail

摘要

Wire arc additive manufacturing (WAAM) offers significant advantages for the fabrication of stainless-steel components; yet, the optimization of process parameters remains critical for achieving desirable geometric and microstructural properties. This study investigates the effects of travel speed, welding current, and wire feed ratio on the layer geometry and microstructure of SS309L stainless steel produced via robotic double-wire MIG welding. Using a Taguchi L9 orthogonal array, the main and interaction effects of these parameters were systematically evaluated. Analysis of variance revealed that wire feed ratio is the most influential factor, contributing (43.6%) to wall height variation, followed by travel speed (22.3%) and welding current (15.9%). A linear regression model was developed to predict wall height, achieving strong agreement with experimental results, with a maximum wall height of 30.79 mm and a deviation below 2.5%. Microstructural analysis showed that the incorporation of cold wire feeding promotes the formation of vertically aligned dendritic structures and a refined granular matrix, resulting in dense, defect-free deposits. In contrast, specimens produced without cold wire feeding exhibited coarser dendritic features and less uniform morphology. These improvements in microstructure are directly associated with enhanced surface quality and mechanical integrity of the additively manufactured walls. The results provide valuable guidance for tailoring WAAM process parameters to achieve precise geometries and consistent material properties in stainless-steel components, thereby informing continuous optimization efforts.