Optimization of wire feed and travel speed parameters based on geometric stability and buy-to-fly ratio in aluminum WAAM

Process parameters in Wire and Arc Additive Manufacturing (WAAM) significantly influence the geometric characteristics of the deposited structures, particularly through heat input and the amount of deposited material. In this study, a TiB2-refined AI-Mg-Si (6063) filler wire, specifically designed for WAAM applications, was used as filler material. Nine walltype samples were produced by WAAM using three levels of travel speed (TS) and three levels of wire feed speed (WFS). The study aims to determine the optimal process parameters that provide the most stable geometric characteristics of the deposited walls and the lowest buy-to-fly (BTF) ratio, i.e., the highest material utilization efficiency. The geometry of the deposited walls was evaluated by analysis of macrosections, including measurements of average bead width, width variability and wall height. The most stable geometry with the lowest buy-to-fly ratio was achieved at intermediate values of WFS and TS. Low travel speeds produced wider layers due to higher heat input, while high travel speeds resulted in thinner layers and lower wall height.