Wire arc additive manufacturing of mild steel

This paper presents an overview of additive manufacturing technologies for the production of metal parts, focusing specifically on wire arc additive manufacturing (WAAM) technologies, which include MIG/MAG welding, TIG welding, and plasma welding. The objective of this study is to highlight the advantages of WAAM over laser or electron beam technologies, particularly in terms of lower investment and operational costs, despite the drawback of lower dimensional accuracy in the produced structures. The research methodology involved analyzing the microstructure and hardness of produced thin wall structures utilizing G3Si1 welding wire, while optimizing welding parameters for achieving smooth surfaces. The use of a welding robot and cold metal transfer (CMT) power source were also explored to enhance production efficiency. Additionally, SprutCAM software was employed to generate the code necessary for the 3D printing of sample parts. The results indicate that WAAM technologies are more suited for producing larger parts due to their productivity, while providing insights into the performance and characteristics of the constructed materials.