Generalised overlapping model for multi-material wire arc additive manufacturing (WAAM)

The single-material overlapping models are incompatible with multi-material wire arc additive manufacturing (WAAM). A newly developed generalised model considers dissimilar adjoining beads in WAAM. geometric of coupled an algorithm identifies the process conditions for two materials to maintain same bead heights. model, implemented stainless-steel and creep-resistant-steel pair, yields significant scientific practical findings. Compared a fixed distance single-material, e.g. 0.66 or 0.738 times width, is complex function individual widths. bi-metallic interface fusion affected by molten metal flow, dimensions, heat input. Contrary prevailing notion flat-top surface intermediate layer ideal multi-layer deposition, slight hill ensures defect-free interface. repeatable walls matrix expected have breakthrough