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<p>Wire arc additive manufacturing (WAAM) is an advanced and promising approach for manufacturing medium to large components due to its high deposition efficiency and cost-effectiveness. In this work, the effect of travel speed on the initial layer deposition of Al-5356 alloy was investigated using the GMAW (Gas Metal Arc Welding) based WAAM process under constant wire feed rate and torch angle. The study revealed that travel speed strongly influences the bead geometry, microstructural evolution, mechanical response, residual stress distribution and crystallographic texture of the deposited material. The lowest speed of 6&#xa0;mm/s yielded the maximum bead height, while 7&#xa0;mm/s yielded the largest bead width and the highest microhardness. Increasing the speed to 8&#xa0;mm/s resulted in higher residual stress and more pronounced texture orientation. These results demonstrate that travel speed is an important parameter in controlling the quality and performance of WAAM-fabricated parts and providing useful guidance for optimising process conditions for specific application requirements.</p>

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Investigation of aluminium parts fabricated by robotic WAAM: influence of travel speed on microstructure and mechanical properties

  • 期刊论文

  • 发表日期：

    2026年2月18日

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  • Sumit K. Sharma,
  • Kashif Hasan Kazmi,
  • Parth Patel,
  • Mukesh Chandra,
  • Amarish Kumar Shukla,
  • Chaitanya Sharma

摘要

Wire arc additive manufacturing (WAAM) is an advanced and promising approach for manufacturing medium to large components due to its high deposition efficiency and cost-effectiveness. In this work, the effect of travel speed on the initial layer deposition of Al-5356 alloy was investigated using the GMAW (Gas Metal Arc Welding) based WAAM process under constant wire feed rate and torch angle. The study revealed that travel speed strongly influences the bead geometry, microstructural evolution, mechanical response, residual stress distribution and crystallographic texture of the deposited material. The lowest speed of 6 mm/s yielded the maximum bead height, while 7 mm/s yielded the largest bead width and the highest microhardness. Increasing the speed to 8 mm/s resulted in higher residual stress and more pronounced texture orientation. These results demonstrate that travel speed is an important parameter in controlling the quality and performance of WAAM-fabricated parts and providing useful guidance for optimising process conditions for specific application requirements.