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<p>Droplet transfer has a strong interrelationship with melt pool behavior, significantly influencing bead morphology and the quality of printed parts in the wire and arc additive manufacturing (WAAM) process. However, this relationship is minimally explored in experiments. To address this gap, this study, for the first time, investigates the mechanism behind droplet transfer, melt pool behavior, and bead profile evolution in the WAAM process using a tungsten inert gas power source. The effects of wire positioning were analyzed, revealing that variations in wire location altered heat transfer dynamics, leading to changes in cooling rates and convection flow, and then changing the bead profile. The findings indicated that when the wire was positioned 4&#xa0;mm above the surface, the melt pool maintained a regular profile. However, when the wire was placed directly on the surface, the melt pool took on an irregular, teardrop-like shape—wider at the front and significantly narrower at the tail. This irregularity resulted from the formation of a bridge current (by-pass current) between wire and arc, which modified heat transfer patterns. Consequently, a dual convection flow emerged, directing molten material from the center to the edges, particularly at the front of the melt pool. These insights contribute to a deeper understanding of the physical mechanisms governing the WAAM process.</p>

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Melt pool dynamics and droplet transfer in single-layer wire and arc additive manufacturing process

  • 期刊论文

  • 发表日期：

    2025年4月26日

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  • Van Anh Nguyen,
  • Deara Supriadi,
  • Xuan Nang Ho,
  • Van Tuan Nguyen,
  • Van Thao Le,
  • Le Huy Vu,
  • The Hung Dinh

摘要

Droplet transfer has a strong interrelationship with melt pool behavior, significantly influencing bead morphology and the quality of printed parts in the wire and arc additive manufacturing (WAAM) process. However, this relationship is minimally explored in experiments. To address this gap, this study, for the first time, investigates the mechanism behind droplet transfer, melt pool behavior, and bead profile evolution in the WAAM process using a tungsten inert gas power source. The effects of wire positioning were analyzed, revealing that variations in wire location altered heat transfer dynamics, leading to changes in cooling rates and convection flow, and then changing the bead profile. The findings indicated that when the wire was positioned 4 mm above the surface, the melt pool maintained a regular profile. However, when the wire was placed directly on the surface, the melt pool took on an irregular, teardrop-like shape—wider at the front and significantly narrower at the tail. This irregularity resulted from the formation of a bridge current (by-pass current) between wire and arc, which modified heat transfer patterns. Consequently, a dual convection flow emerged, directing molten material from the center to the edges, particularly at the front of the melt pool. These insights contribute to a deeper understanding of the physical mechanisms governing the WAAM process.