Wire arc additive manufacturing is a newer additive manufacturing technology which presents a promising alternative to traditional subtractive manufacturing for fabricating components with complex geometry. Current research in this field is focused on improving geometry accuracy and surface finish to produce complex-shaped components. Another goal is to lower residual stresses and distortions which are caused by thermally induced stress during arc weld surfacing. The research was focused on the influence of welding parameters and welding strategies on the surface waviness and weld surfacing material efficiency, the influence of the torch angle on the shape of produced walls and the weld surfacing material efficiency. We investigated the influence of bead overlapping and the interpass weld temperature on the produced welding defects in the product.
With the increasing welding speed, the wall height and width were decreasing regardless of welding parameters and welding strategy because less filler material is added. The weld surfacing material efficiency for narrow and tilt walls did not change fundamentally at different welding parameters and welding strategy. By increasing the overlap between the beads the welding defects within the wall increased, while it decreased with the increasing interpass weld temperature.