Abstract:
Wire Arc Additive Manufacturing (WAAM) is an advanced 3D metal printing
technique that enables the fabrication of complex, large-scale components with
minimal material waste. Its ability to control deposition parameters has made it
particularly useful for creating Functionally Graded Materials (FGMs), which
exhibit a gradual variation in composition and structure. This paper explores recent advancements in the fabrication of FGMs using WAAM, focusing on
material combinations, process optimization, and the resulting microstructural
and mechanical properties. Through numerical analysis, it was observed that
controlling the wire feed rate and deposition speed significantly influences the
mechanical properties, including tensile strength and hardness. For instance,
increasing the wire feed rate from 2 mm/s to 8 mm/s improved the ultimate
tensile strength by 15%, but a further increase led to a 10% reduction due to
incomplete fusion between layers. Additionally, post-processing techniques
such as laser polishing reduced surface roughness by up to 80%, significantly
enhancing the component's performance in wear-sensitive applications. This
study highlights the importance of optimizing process parameters and post
processing techniques to enhance the functionality and reliability of FGMs
fabricated by WAAM.
