Optimization of Forging Parameters for Enhanced Mechanical Properties of Wire Arc Additive Manufacturing‐Deposited High‐Strength Low‐Alloy Steel Bead

This study investigates the influence of key forging parameters such as temperature, thickness ratio, and cooling medium on the mechanical properties of high‐strength low‐alloy steel beads produced via wire arc additive manufacturing (WAAM). An L9 Taguchi orthogonal array is employed to optimize the experimental design and minimize testing costs, while analysis of variance (ANOVA) is applied to evaluate the significance of each factor. The results indicate that the optimal condition for maximum tensile strength (≈738 MPa) is achieved at a forging temperature of 500 °C, a thickness ratio of 0.60, and water cooling, whereas the highest ductility (≈42% elongation) is obtained at 900 °C, a thickness ratio of 0.75, and air cooling. Scanning electron microscopy reveals that these mechanical responses are driven by microstructural evolution, including grain refinement and phase transformations, tailored by the selected forging conditions. These findings demonstrate that combining WAAM with optimized forging parameters enables the development of components with balanced strength and ductility, suitable for demanding applications in aerospace, automotive, and shipbuilding industries.