WAAM: Optimization of Start and End Zones of the Weld Bead, Case of S235JR Carbon Steel

In recent years, metal additive manufacturing has seen significant growth, offering manufacturers innovative capabilities through sequential layer deposition. Among these techniques, wire-arc additive manufacturing has emerged prominently. However, challenges persist in optimizing welding parameters to control layer dimensions accurately. One overlooked area in existing literature is the initial distortions in walls during wire arc additive manufacturing, especially in weld bead initiation and extinction zones, which can compromise component quality. While some studies propose overlaying start zones onto extinction zones to address these issues, this approach may introduce structural problems like insufficient penetration and potential cracking, affecting the final product’s integrity. Our research project aims to optimize parameters at both the start and end of the weld bead to ensure consistent production of defect-free weld lines and ideal walls, particularly those made of S235JR carbon steel. Employing the Design of Experiments method, we optimized weld bead initiation and extinction zones, with a focus on measuring widths and allowances. Although initial findings are promising, further validation through additive wall manufacturing is necessary to confirm the effectiveness and reliability of the optimized parameters for high-quality metal additive manufacturing processes.