Investigation of Process Parameters for Quality Deposition of AL5356 using Cold Metal Transfer Wire Arc Additive Manufacturing (CMT-WAAM)

In this study, an investigation of mechanical characteristics, microstructure, and the optimal parameters for wall deposition using response surface methodology is done. Testing for microhardness in the deposition directions, Charpy impact, and tensile testing at room temperature were used to evaluate the printed structures. The tensile test results showed that the center layers exhibit a maximum yield strength of 191 MPa, ultimate tensile strength of 321 MPa, and elongation of 16.03%. The toughness measurement by Charpy testing shows the maximum value of 23.57 J in the core layer. The top layer has a hardness of 65.73Hv, higher than the rest of the sample. The impact of SOD, TS, and WFR on BW, BH, and AR were determined after optimizing the parameters. The responses find that the optimal parameters for single-layer deposition are a wire feed rate (WFR) of 7 mm/min, a standoff distance (SOD) of 20mm, and a travel speed (TS) of 20 cm/min. Wire Arc Additive Manufacturing (WAAM) parameters were investigated using additional statistical methods, including Analysis of Variance (ANOVA) and the desirability function.