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<p>The wire arc additive manufacturing (WAAM) method has garnered significant attention in component part due to its remarkable deposition rate. The precision of the fabricated parts hinges on the accuracy of layer deposition, presenting a challenge in achieving a flat surface for subsequent layers. An appropriate model is pivotal for determining bead positioning and enhancing manufacturing precision. In this study, the enhanced flat-top overlapping model (EFOM) based on the dissimilar beads cross-section area strategy was proposed for WAAM. Previous models have assumed that each bead weld is placed on a flat surface. This study introduces a novel model that considers the placement of bead welds on both the base plate and the surface of the preceding bead weld. The proposed model presupposes a reduced cross-sectional area for the second bead weld to achieve improved flatness during deposition. A mathematical relationship elucidating the correlation between the distance separating welds and the cross-sectional area of the second bead weld is derived from this model. This mathematical framework enables the calculation of the step-over distance. After placing multiple beads alongside the initial profile bead welds, an assessment is conducted employing laser scanning techniques. Consequently, the flatness of the surface is evaluated using the umbrella curvature method. Results demonstrate that EFOM achieves a surface flatness with an average deviation of 0.1344&#xa0;mm in the flat section and 0.0965&#xa0;mm for scanned point clouds. This high precision minimizes post-processing needs, making EFOM highly suitable for the fabrication of multi-layered parts.</p>

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A novel multi-bead overlapping model for wire arc additive manufacturing (WAAM) processes with dissimilar beads area strategy

  • 期刊论文

  • 发表日期：

    2025年12月2日

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  • Abolfazl Foorginejad,
  • Mohammad Zarei,
  • Sayyed Mohammad Emam,
  • Seyed Mohammad Javad Hosseini Baghdadabadi

摘要

The wire arc additive manufacturing (WAAM) method has garnered significant attention in component part due to its remarkable deposition rate. The precision of the fabricated parts hinges on the accuracy of layer deposition, presenting a challenge in achieving a flat surface for subsequent layers. An appropriate model is pivotal for determining bead positioning and enhancing manufacturing precision. In this study, the enhanced flat-top overlapping model (EFOM) based on the dissimilar beads cross-section area strategy was proposed for WAAM. Previous models have assumed that each bead weld is placed on a flat surface. This study introduces a novel model that considers the placement of bead welds on both the base plate and the surface of the preceding bead weld. The proposed model presupposes a reduced cross-sectional area for the second bead weld to achieve improved flatness during deposition. A mathematical relationship elucidating the correlation between the distance separating welds and the cross-sectional area of the second bead weld is derived from this model. This mathematical framework enables the calculation of the step-over distance. After placing multiple beads alongside the initial profile bead welds, an assessment is conducted employing laser scanning techniques. Consequently, the flatness of the surface is evaluated using the umbrella curvature method. Results demonstrate that EFOM achieves a surface flatness with an average deviation of 0.1344 mm in the flat section and 0.0965 mm for scanned point clouds. This high precision minimizes post-processing needs, making EFOM highly suitable for the fabrication of multi-layered parts.