This study investigates the correlation between deposition parameters and the bead geometry of ER 4043 aluminium alloy structures fabricated via Wire Arc Additive Manufacturing (WAAM). Utilising a Gas Metal Arc Welding (GMAW) setup, a Central Composite Design (CCD) was implemented to systematically evaluate the influence of wire feed rate (WFR), tool speed (TS), and contact tip-to-work distance (CTD). Response Surface Methodology (RSM) and Analysis of Variance (ANOVA) were employed to develop predictive regression models and define the optimal processing window. The investigation revealed that a configuration of TS = 5.05 mm/s, WFR = 5.04 mm/s, and a CTD = 10.37 mm minimised surface roughness 2.652 Ra and bead width 3.727 mm while maximising bead height 3.805 mm. These findings provide a robust framework for parameter optimisation in WAAM, ensuring the production of high-fidelity aluminium components with superior surface and structural characteristics.
Kashif Hasan Kazmi (Sun,) studied this question.