Precision Bead Geometry Optimization in GMAW-Based WAAM Using 1.36Cr–0.5Mo Steel Metal-Cored Wires

Abstract The main question of this research was to optimize process parameters to inherently improve the performance of Gas Metal Arc Welding (GMAW) in Wire Arc Additive Manufacturing (WAAM) using metalloy 80B2, a gas shielded metal-cored wire comprising 1.00-1.50% chromium and 0.50% molybdenum steel. The effect of input parameters, which are travel speed, shielding gas mix, and voltage, was assessed with regard to bead geometry associated with Bead Width (BW), Bead Height (BH), and Depth of Penetration (DOP). To identify the best set of variables to experiment on, Box Behnken Design within the response surface methodology was utilised. Analysis of variance (ANOVA) was also used to justify the effectiveness and relevance of the correlations developed using the experimental results. The findings showed that the speed of travel had a stronger impact on DOP and BH, whereas the voltage almost solely affected the BW. Main effect and residual plots were used to determine the most significant independent factors as well as to determine the accuracy of the developed models of DOP, BH, and BW. Grey Relational Analysis (GRA) was also used to determine the best setting of input parameters when performance was required to provide the best possible result. The most favourable parameters received as a result of GRA were: voltage = 26 V, travel speed = 6 mm/s, 5 percent CO₂ in the shielding gas mixture. Experimental conduct on these optimized parameters found an average deviation reversal of less than 6 percent between actual and the forecasted measures. Additionally, the multilayer structures synthesized under such conditions did not show any indications of disbandment.