Intelligent Additive Manufacturing for improved Fatigue strength: influence of the process parameters

Abstract

Arc‐based metal additive manufacturing is a highly effective method for producing complex, medium‐ to large‐scale parts. However, ensuring defect‐free results remains a challenge due to the uncertainty related to the impact of manufacturing parameters on the final product. This often necessitates a time‐consuming trial‐and‐error approach to optimize conditions. Optimizing manufacturing parameters is necessary for “ideal” material and geometrical properties in WAAM, which is a significant barrier for mainstream adoption. In addition, qualifying a WAAM component as a structural element can be problematic without an in‐depth analysis of its behaviour, which often involves destructive testing. To address this issue, a systematic study was conducted. The investigation evaluated various welding transfer modes, while varying welding currents and robot travel speeds. Experiments on single‐bead, ten‐layer walls identified a process window for stable geometry and revealed relationships between process parameters, layer geometry and material behaviour.