Parametric optimization of bead geometry in wire arc additive manufacturing of aluminum alloy

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.