Influence of wire feeding speed on residual stress distribution in 205C aluminum alloy fabricated by CMT+P additive manufacturing

Residual stress and warping remain critical challenges in wire arc additive manufacturing (WAAM) of high-strength aluminum alloys. This study explores the influence of wire feeding speed on the thermo-mechanical response of 205C aluminum alloy using the CMT+P process. Double-bead structures were fabricated on 2319 substrates under four feeding speeds, with residual stress and deformation quantified via 3D scanning and ultrasonic testing. The results reveal a strong correlation (Pearson > 0.9) between residual stress and warping. A feeding speed of 6.8 m/min yielded the most stable outcome, minimizing WD stress (179 MPa), variance (193 MPa 2 ), and warping (<3.3 mm). A quadratic regression model (R 2 > 0.96) captured these trends effectively. The underlying mechanism was interpreted using Fourier’s law and thermoelastic theory. While the analysis focused on feeding speed, the framework supports future extension to multi-parameter modeling and real-time control strategies, such as closed-loop thermal monitoring or path adaptation in WAAM.