Parameter Optimization of WAAM with Pulsed GMAW for Manufacturing Propeller-Shaped Blade.

The experiments of wire arc additive manufacturing (WAAM) with general pulsed gas metal arc welding (GMAW) machine were performed to optimize process parameters. As optimized conditions, 140A welding current, 34 V welding voltage, 40 cm/min welding speed, and 15 mm contact tip to work distance (CTWD), were selected. Welding current and voltage affected heat input. Lower deposition, short circuit mode, and spatters were obtained by insufficient heat input. The melting of previous layer and lower height were obtained by excessive heat input. Welding speed and CTWD affected surface state and arc stability. Unsound surface and bead shape due to short circuit mode and spatters were observed in slow welding speed and short CTWD conditions. Arc instability were also observed in fast welding speed and long CTWD conditions. With the optimized process parameter, curved propeller shape blade was manufactured by the change of robot arm teaching point. It can be considered that the desired sufficient quality was obtained due to curved shape. [ABSTRACT FROM AUTHOR]