Characterizing Surface Waviness of Aluminum Alloy: An Approach to Minimize Post-Processing in Wire Arc Additive Manufacturing (WAAM) Production

Document Type

Article

Publication Date

11-1-2025

Abstract

Wire Arc Additive Manufacturing (WAAM) offers high deposition rates and cost-effective production of large metal components but suffers from poor surface quality, particularly surface waviness, which increases post-processing requirements and limits industrial adoption. Since waviness directly impacts structural integrity, resource efficiency, and industrial applicability, understanding how process parameters govern this feature is critical for reducing post-processing requirement. This study systematically investigated the influence of voltage, travel speed, and wire feed speed on surface waviness in aluminum alloy walls fabricated by WAAM. A two-level factorial design with 16 experiments was conducted, and surface waviness was quantified using height gauge measurements relative to the expected bead height. Statistical analyses, including ANOVA and multiple linear regression, were applied to evaluate parameter significance. The results revealed that wire feed speed was the most influential parameter, showing a strong positive correlation with waviness due to excess material deposition. Voltage exhibited a weaker, stabilizing effect, with higher values marginally reducing waviness through improved arc stability, while travel speed had negligible influence within the studied range. The regression model achieved an (Formula presented.) 0.389, with validation tests indicating reasonable predictive accuracy. These findings demonstrate that controlling wire feed speed is critical for minimizing waviness, while higher voltage may serve as a secondary stabilizing factor. The study was limited to surface waviness however, future work should consider the role of thermal accumulation, inter-pass temperature, and external disturbances on surface stability. Such insights could enable adaptive parameter control strategies to further reduce post-processing needs and enhance the industrial viability of WAAM.

Publication Title

Journal of Manufacturing and Materials Processing

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