Numerical Analysis of Heat Accumulation During Wire Arc Additive Manufacturing

The wire arc additive manufacturing (WAAM) process is one of the fast emerging metal additive manufacturing techniques. WAAM is known for its high deposition rates and relatively lower costs, which makes it suitable for the fabrication of large parts. Heat accumulation is one of the key challenges with WAAM. As layers are deposited during WAAM, heat accumulates due to insufficient cooling. This continues as the number of layers increases, which affects the geometry and mechanical performance of the deposited part. In this study, the WAAM process is modelled numerically, and the heat accumulation patterns are analysed. The numerical results compare well against experimental observations available in the literature. Further, the influence of interpass dwell time on the accumulated heat is discussed through the quantification of heat.