Prediction of bead layer geometry in P-GMAW wire arc additive manufacturing of aluminium alloys

The paper presents a study of the influence of the parameters of pulsed arc surfacing on the geometry of the deposited metal in wire-arc additive manufacturing(WAAM) using aluminum-magnesium alloys. As variable parameters of the pulse-arc process, the wire feed speed, the working tool movement speed, and the drop size were chosen. The geometric parameters of the elements were evaluated by measuring the width and height of the layer, as well as determining the allowance for subsequent machining. The optimal growth regimes are determined, which are characterized by the stable formation of single beads on the substrate. The width and height of the bead along the entire length changed insignificantly. It has been established that the parameters of the current pulses affect the quality of the fusion of the layers to each other and the droplet diameter affects the allowance for subsequent machining (criterion R). Based on the results of the factorial experiment, regression models were obtained that can be used to predict the geometric parameters of the layer of a thin-walled element deposited using the technology WAAM, taking into account the R-criterion.