Bi-polynomial fourth-order weld bead model for improved material utilization and accuracy in wire-arc additive manufacturing: A case of transverse twin-wire welding

With the gradual evolution of metal additive manufacturing (AM) as a viable option for realizing complex parts, research focus has shifted from mere geometric realization to higher material deposition rate without significant loss accuracy. This work aims demonstrate potential traverse twin-wire welding produce asymmetric weld beads, providing an extra control factor in bead shape and component accuracy while retaining high rates. A new model - bi-polynomial fourth-order is developed linked process conditions. The higher-order more responsive variation accurate than traditional models. Compared conventional single polynomial models, which are limited symmetrical cross-sectional bead, can also simulate asymmetrical bead. offset integrated with product features assess time fabrication (number passes) post-machining wastage. usefulness integration demonstrated manufacture candidate multi-pass multi-layer component. It envisaged that investigation will facilitate large-scale wire-arc AM use transverse welding.