Optimization of Bead Morphology for GMAW-Based Wire-Arc Additive Manufacturing of 2.25 Cr-1.0 Mo Steel Using Metal-Cored Wires

The fabrication of components involves the deposition multiple beads in layers for wire-arc additive manufacturing (WAAM). WAAM performed using gas metal arc welding (GMAW) allows parts through multiple-bead multi-layer deposition, which depends on process variables. Thus, selection parameters along with their required levels is mandatory to deposit WAAM. To obtain desired parameters, bead-on-plate trials were taken base plate low alloy steel by following an experimental matrix produced Box–Behnken design (BBD) GMAW-based Wire feed speed, travel and voltage chosen as input bead width height output parameters. Furthermore, robustness adequacy obtained regression equations analyzed analysis variance (ANOVA). For both responses BW BH, values R2 adj. found be near unity, has shown fitness model. Teaching–learning-based optimization (TLBO) technique was then employed optimization. Within selected range variables, single-objective result showed a maximum (BH) 7.81 mm, minimum (BW) 4.73 mm. tackle contradicting nature responses, Pareto fronts also generated, provides unique non-dominated solution. Validation conducted reveal ability suitability TLBO algorithm. discrepancy between anticipated measured observed negligible, deviation less than 5% all validation trials. This demonstrates success established model optimum feasible settings determined after further tuning. A structure free from any disbonding successfully manufactured at optimized authors suggest that parametric would beneficial layer-by-layer weld components.