| Abstract Scope |
Wire Arc Additive Manufacturing (WAAM) has many process parameters with complex interactions in the formed melt pool that affect its ability to obtain consistent depositions. This work introduces a novel dimensionless number, the WAAM Number, that characterizes bead geometry by encapsulating multiple process parameters, including ac voltage, arc current, mass flow rate, travel speed, and intrinsic material properties into a single independent variable. This WAAM number presents a generalizable representation for predicting bead geometry, width, and height, and can be applied across multiple materials, welding modes, and WAAM systems. The utility of the WAAM number for characterizing and predicting bead geometry is validated through analysis of single-track depositions of Al5Mg and mild steel using two short circuit welding modes on two separate WAAM machines. |