Wire-arc additive manufacturing: Process optimization, advancements, in-process data monitoring, and material characterization

This thesis explores the optimization and characterization of Wire Arc Additive Manufacturing (WAAM) for low-carbon steel, aiming to enhance deposition quality, geometrical precision, and material properties. Preliminary experiments established a processing window by analyzing the influence of key process parameters power, travel speed, wire feed speed, and stand-off distance on bead geometry and material properties. Advanced methodologies, such as force air cooling, in-process data monitoring and microstructural analysis, were utilized to evaluate the thermal and mechanical behavior of WAAM-fabricated components.