Abstract The use of the GMAW-P process shows promise in expanding the possibilities of metal additive manufacturing due to its high deposition rates, lower material costs compared to other processes, and due to its ability to provide better control over heat input and melt pool during operation. Since the droplet detachment mode is an important factor for process stability, further investigation is justified regarding the impact of the different modes on the formation of deposited material layers. In order to facilitate parameter selection for this and other research related to droplet detachment conditions with stainless steel 308L, it was proposed to map the regions of One Drop per Pulse, Multiple Drops Per Pulse, and One Drop per Multiple Pulses. Furthermore, the aim is to validate the use of the detachment constant as a means to estimate the detachment condition for a specific set of peak current and peak time. To perform this mapping, a high-speed camera was used to visually validate the droplet detachment modes obtained by varying the peak time and peak current. The results allowed the determining intervals for each of the three droplet detachment modes. It was also observed that the detachment constant can be a good approximation for the phenomenon, provided the same wire, contact-tip-to-work distance, shielding gas, and mean current are used.
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Ribeiro et al. (2024) studied this question.
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