Influence of Component Geometry and Process Parameters on Mechanical Performance of Wire‐Arc Additive Manufactured Carbon Steel Tubes

Abstract

Wire Arc Additive Manufacturing (WAAM) of carbon steels has gained significant attention due to its high deposition rates and cost efficiency compared with conventional fabrication methods, particularly casting. Nevertheless, challenges persist in achieving consistent weld bead geometry, mechanical reliability, and process repeatability, often resulting in irregular geometries, reduced mechanical performance, and a higher likelihood of defects. Recent experimental and computational investigations on WAAM‐fabricated carbon steels have shown that key manufacturing parameters—including wire feed speed, travel speed, voltage, and heat input—strongly influence weld bead height, width, and mechanical properties. This study aims to bridge these aspects by demonstrating the influence of welding parameters, component height, orientation, and path planning through a combined experimental and numerical approach. A series of 3 carbon steel tubes were fabricated under three welding parameters varying heat input and travel speed. Experimental characterization of as‐built coupons, coupled with the simulation outputs, revealed correlations between processing parameters, component height and orientation, with tensile strength. These integrated findings enhance the understanding of the interdependence between manufacturing and material properties in WAAM steel components.