Multi-objective optimization of robotic WAAM parameters for Inconel 718: balancing path precision and build rate

Wire Arc Additive Manufacturing, particularly with Cold Metal Transfer technology, has emerged as a promising approach for fabricating large metallic components. However, achieving high geometric precision while maintaining an efficient build rate remains a fundamental challenge limiting industrial application. This study presents a multi-objective optimization framework for key WAAM parameters, Wire Feed Rate, Welding Torch Travel Speed, number of layers, and wall thickness using Inconel 718 feedstock. The optimization aimed to minimize geometric deviation and maximize deposition efficiency. A tailored path-planning strategy, developed with strict geometric considerations, was integrated to improve accuracy and reduce material waste. Experimental validation using a robotic CMT setup demonstrated significant improvements in wall uniformity, surface smoothness, and dimensional accuracy, along with reduced cycle time without compromising quality. The proposed optimization and path-planning framework is validated as an effective approach for manufacturing high-integrity, geometrically complex components, offering notable potential applications where precision and efficiency are critical.