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<p>Nickel-based alloy coaxial wire-feed arc additive manufacturing has become a significant method for producing complex metallic parts with high-performance characteristics. Nevertheless, challenges such as unstable droplet transfer, poor track quality, and spattering remain, affecting process efficiency and quality. This study investigates the effects of arc current and voltage on droplet transfer behavior and track formation. The results indicate that below 240 A, unstable short-circuit transfer leads to poor track quality and severe spattering. Between 240 and 260 A, droplet transfer stabilizes into a steady short-circuit mode, improving track formation and significantly reducing spattering. At 260 A, droplet transfer transitions to spray mode, enhancing melt pool fluidity and heat input control. Within the optimal voltage range (25–27 V), track quality improves, exhibiting uniform width, moderate depth, a smooth surface, minimal spattering, good metallic luster, and slight oxidation. These findings highlight the critical role of arc parameters in optimizing droplet transfer and track formation, providing valuable insights for improving process efficiency and final part quality in nickel-based alloy coaxial wire-feed arc additive manufacturing.</p>

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Droplet transfer behavior and track formation in nickel-based alloy coaxial wire-feed arc additive manufacturing

  • 期刊论文

  • 发表日期：

    2026年6月3日

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  • Yajie Chu,
  • Gongchen Zhu,
  • Wenhui Yuan,
  • Xu Zhang

摘要

Nickel-based alloy coaxial wire-feed arc additive manufacturing has become a significant method for producing complex metallic parts with high-performance characteristics. Nevertheless, challenges such as unstable droplet transfer, poor track quality, and spattering remain, affecting process efficiency and quality. This study investigates the effects of arc current and voltage on droplet transfer behavior and track formation. The results indicate that below 240 A, unstable short-circuit transfer leads to poor track quality and severe spattering. Between 240 and 260 A, droplet transfer stabilizes into a steady short-circuit mode, improving track formation and significantly reducing spattering. At 260 A, droplet transfer transitions to spray mode, enhancing melt pool fluidity and heat input control. Within the optimal voltage range (25–27 V), track quality improves, exhibiting uniform width, moderate depth, a smooth surface, minimal spattering, good metallic luster, and slight oxidation. These findings highlight the critical role of arc parameters in optimizing droplet transfer and track formation, providing valuable insights for improving process efficiency and final part quality in nickel-based alloy coaxial wire-feed arc additive manufacturing.