Effect of cold metal transfer-based wire arc additive manufacturing parameters on geometry and machining allowance

Wire arc additive manufacturing is a process with great potential and in full expansion for structural, maintenance, and large-scale product development. It is gaining interest due to its low buy-to-fly ratio. Nevertheless, its major flaw is the low geometric accuracy and the wavy surfaces of the printed parts. To ensure that the requirements of the final part are respected, the dimensions and the minimum quantity of material to be machined have to be specified. Thus, machining allowance and part dimensions are elements that were quantified based on a design of experiments (DOE) and thermal analysis. It was used to determine the effects of cold metal transfer (CMT) parameters on them. For instance, it was found that travel speed and interpass time have a major influence on height, width, and machining allowance. Specific way to achieve the desired requirements is discussed.