Numerical analysis on the effect of processparameters on deposition geometry in wirearc additive manufacturing

Here we develop a two-dimensional numerical model of wire and arc additive manufacturing(WAAM) to determine the relationship between process parameters and deposition geometry,and to reveal the influence mechanism of process parameters on deposition geometry. From thepredictive results, a higher wire feed rate matched with a higher current could generate a largerand hotter droplet, and thus transfer more thermal and kinetic energy into melt pool, whichresults in a wider and lower deposited layer with deeper penetration. Moreover, a higher preheattemperature could enlarge melt pool volume and thus enhance heat and mass convection alongboth axial and radial directions, which gives rise to a wider and higher deposited layer withdeeper penetration. These findings offer theoretical guidelines for the acquirement of acceptabledeposition shape and optimal deposition quality through adjusting process parameters infabricating WAAM components.