Influence of Wire Feed Speed and Torch Speed on the Mechanical Properties of Wire Arc Additively Manufactured Stainless Steel

Wire arc additive manufacturing (WAAM) enables 3D printing of large high-value metal components. However, integrating WAAM into production lines requires a critical understanding of the influence of process parameters on the resulting material characteristics. As such, this research investigates the relationship between WAAM wire feed speed (WFS) and torch speed (TS) on the resulting mechanical characteristics of 316LSi thick parts (2.5 cm (0.98 in.)). The experimental procedure is informed by a training matrix that allows parametric analysis of WFS and TS on the ultimate tensile strength (cult), yield strength (s(y)), elastic modulus (E), failure strain (e(f)), hardness (HV0.5), and dimensional accuracy (D-a) of the printed samples. The research found that WAAM-processed 316LSi parts feature isotropic material properties despite variations in WFS and TS. The surrogate model developed in this study offers five significant polynomial models capable of accurately predicting the influence of WAAM process parameters on s(ult), s(y), e(f), E, and D-a. The research found TS to be the most significant WAAM process parameter in comparison to WFS for s(ult) and e(f). On the contrary, s(y), E, and Da were found to be primarily driven by WFS as opposed to TS. Overall, the paper for the first time presents an accurate surrogate model to predict the mechanical characteristics of WAAM 316LSi thick parts informed by wire feed speed and torch speed. The study demonstrates that the mechanical properties of WAAM-processed steel are primarily influenced by the underlying process parameters offering significant potential for tunable performance. [DOI: 10.1115/1.4063108]

Automated summary

This research investigates the influence of process parameters on the mechanical characteristics of metal components produced through wire arc additive manufacturing (WAAM). The study found that WAAM-processed parts exhibit isotropic material properties and developed a surrogate model to accurately predict the effects of process parameters. Torch speed was identified as the most significant parameter, while wire feed speed primarily influenced yield strength, elastic modulus, and dimensional accuracy. This study provides valuable insights for predicting the mechanical properties of WAAM-produced parts.