Effect of Wire Arc Additive Manufacturing Process Parameters on Bead Geometry and Porosity Formation of 5356 Aluminum alloy

Abstract

Wire Arc Additive Manufacturing offers significant potential for producing large, complex aluminum parts with reduced cost and material waste. This study investigates the effects of process parameters, including voltage, scanning speed, and energy density, on the bead geometry and porosity formation of aluminum alloy ER5356 in the WAAM process. A series of 36 single-track aluminum samples were fabricated under varying welding conditions. The results demonstrate that increasing voltage enhances bead width and penetration but reduces bead height and contact angle. Similarly, higher scanning speeds result in smaller bead dimensions. Energy density was found to influence both bead geometry and porosity, with higher energy densities increasing porosity. Through current study the optimal voltage levels used vary between (22-24 V) to contribute into track formation consistently. Additionally, the porosity decreased with higher scanning speed and lower energy density. These findings provide valuable insights into optimizing WAAM parameters for aluminum alloys, reducing defects, and improving material performance for industrial applications.