Forming appearance analysis in multi-layer single-pass GMAW-based additive manufacturing

Additive manufacturing based on gas metal arc welding (GMAW) is gaining increasing popularity as the process allows fabrication of fully dense parts with high material efficiencies and deposition rates. This paper aims at studying forming characteristics of multi-layer single-pass parts. Influences of arc current, deposit velocity, and heat input on layer formation were analyzed by using a passive vision sensor. Based on the results, the arc current has the greatest effect on the forming appearance, and a better understanding of the forming characteristics and process specification interval in multi-layer single-pass GMAW-based additive manufacturing can be obtained. Some newly improved GMAW methods were considered to improve deposition rates in multi-layer single-pass additive manufacturing process.