Selection of Optimal Process Parameters for Wire Arc Additive Manufacturing

Abstract This paper is about the optimal selection of process parameters for Wire Arc Additive Manufacturing technology, an emerging solution for additive production of metal parts. In particular, the selection of the process parameters is based on the evolution of the microstructure and on the mechanical properties of the final samples obtained through the successive deposition weld beads of a ER70S-6 steel, according to the AWS legislation. The feed rate and the heat input during the deposition of the weld beads have been varied, in order to understand how the temperature reached by the samples can affect the final product mechanical characteristics. The final cooling has been carried in calm air at room temperature and between the deposition of a weld bead and the following one it has been imposed a pause of 60s. The tests on mechanical properties carried out have been: A full experimental campaign that includes: macrographic observations, micrographic observations and Vickers microhardness. The analysis of these tests has highligthed that by varying the process parameters, the samples do not have substantial differences between them. Instead, a microstructure that evolves from pearlitic-ferritic grains until bainitic lamellae along the vertical direction of the samples has been observed by micrographic analysis and confirmed by microhardness measurements