Experimental and Numerical Study of the Wire Arc Additive Manufacturing (WAAM) Process

Wire Arc Additive Manufacturing (WAAM) is an additive manufacturing process that utilizes an electric arc to melt and deposit metal wire layer by layer, creating a three-dimensional component. This process offers several advantages, such as the ability to produce large-sized parts. It is increasingly being utilized in industries for the production of components for aerospace, automotive, shipbuilding, and other applications. However, it also comes with drawbacks, including low surface resolution and the need to manage deformations and residual stresses. Continuous research and development in this technology are crucial to optimize manufacturing parameters and enhance the mechanical properties and quality of produced parts. In this study, an experimental investigation was conducted to determine the optimal parameters of the WAAM process for producing complex parts. Simple and complex components were fabricated using this process. A numerical model of the WAAM process was developed using the LS-DYNA code. This numerical simulation can aid in understanding the material behavior during the welding process.