A comprehensive prediction model of bead geometry in wire and arc additive manufacturing

To explore the effect of process parameters on the bead geometry in cold metal transfer wire arc additive manufacturing(CMT-WAAW), the response surface optimization method was adopted in this paper. According to previous experiments, some process parameters were selected as independent variables. They are wire feed speed(WFS), traveling speed(TS) and substrate temperature(ST). Some geometric parameters of the welding bead were selected as dependent variables. They are the track width (w), layer height (h), penetration (p), accumulated area (A2), penetration area (A1), aspect ratio (B) and dilution ratio (D). In the given parameter interval, the prediction model behaves good. The relative error of bead size between actual value and predicted value are all within 5%. And five sets of verification experiment were carried out to prove that the accuracy of the developed model.