- Wire arc directed energy deposition (DED-Arc) using a gas metal arc (GMA) welding power source is cited as DED-GMA that fabricates a part by layer-by-layer deposition of molten wire droplets along horizontal and out-of-position inclined trajectories. For the out-of-position trajectories, a smooth deposition of material is impaired by the gravitational force on the molten wire droplets, resulting in uneven and inconsistent deposit profiles. We present here a detailed experimental investigation to realize the effect of the out-of-position inclinations on the quality of the deposited structure for DED-GMA with a steel and an aluminium filler wire. The evolution of the droplet transfer and melt pool during the out-of-position inclined deposition is probed through high-speed videography at different baseplate angles and commonly used scanning strategies. An analytical model is proposed further based on force equilibrium analysis for a prior estimation of the out-of-position inclined depositWire arc directed energy deposition (DED-Arc) using a gas metal arc (GMA) welding power source is cited as DED-GMA that fabricates a part by layer-by-layer deposition of molten wire droplets along horizontal and out-of-position inclined trajectories. For the out-of-position trajectories, a smooth deposition of material is impaired by the gravitational force on the molten wire droplets, resulting in uneven and inconsistent deposit profiles. We present here a detailed experimental investigation to realize the effect of the out-of-position inclinations on the quality of the deposited structure for DED-GMA with a steel and an aluminium filler wire. The evolution of the droplet transfer and melt pool during the out-of-position inclined deposition is probed through high-speed videography at different baseplate angles and commonly used scanning strategies. An analytical model is proposed further based on force equilibrium analysis for a prior estimation of the out-of-position inclined deposit profile, which can help design dimensionally consistent and structurally sound parts using DED-GMA.…

