The effect of the repetitive process of WAAM and cutting on the shape and mechanical properties.

Abstract

Wire Arc Additive Manufacturing (WAAM) offers significant advantages such as low cost and high build speed among additive manufacturing techniques. However, it suffers from cumulative height errors leading to poor shape accuracy and slag formation from deoxidizers causing arc ignition failures. To address these issues, this study explores a hybrid process combining WAAM and machining, specifically proposing interlayer cutting. Using a 5-axis machining center equipped with a welding torch, we employed mild steel wire on SS400 base plates. Comparative evaluations reveal that interlayer cutting effectively reduces arc ignition failures and improves shaping accuracy. Tensile tests confirm that interlayer cutting contributes to enhanced mechanical properties, with increased frequency of interlayer cutting further amplifying these improvements. This research demonstrates that integrating WAAM and machining offers a viable solution for achieving high-precision and high-quality manufacturing, addressing both the shape accuracy and mechanical property challenges inherent in WAAM.