Study of different stick-out heights in the additive manufacturing process

Abstract

This article examines the effects of different Stick-out heights in the Wire Arc Additive Manufacturing (WAAM) process, focusing on the dimensional and microstructural changes of the fabricated parts. The WAAM method, which combines an electric arc and metal wire as feedstock, offers advantages such as high deposition rates and versatility in material selection. The study involved producing test specimens with variations in Stick-out heights (10 mm, 15 mm, 20 mm, and 30 mm), evaluating parameters such as current consumption, part dimensions, and microstructural characteristics. The results indicated that increasing the Stick-out height raises current consumption and causes dimensional variations, resulting in taller and narrower specimens. Metallographic analyses showed that higher Stick-out heights impair microstructural homogeneity, promoting porosity formation. It is concluded that smaller Stick-out heights, such as 10 mm and 15 mm, are more suitable for optimizing the mechanical properties and quality of parts produced by the WAAM process.