Investigation of a Multi-Cathode TIG Arc Process for Additive Manufacturing Applications

Investigation of a Multi-Cathode TIG Arc Process for Additive Manufacturing Applications | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Investigation of a Multi-Cathode TIG Arc Process for Additive Manufacturing Applications Paul Schilling, Tim Ungethüm, Paul Sanderbrand, Hans Christian Schmale This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7618430/v1 This work is licensed under a CC BY 4.0 License Status: Under Review Version 1 posted 5 You are reading this latest preprint version Abstract This study investigates a novel tugsten inert gas double-electrode (TIG-DE) welding process with integrated coaxial hot-wire feeding for additive manufacturing applications. By combining arc generated by multiple cathodes with independent wire preheating, the process aims to overcome the limitations of conventional single-electrode TIG systems, particularly with respect to directional dependence and limited deposition rates. A custom-built demonstrator system was used to systematically analyze the arc behavior, weld bead formation, and process stability under various parameter conditions. Arc pressure measurements confirmed the isotropy of the arc shape under optimized electrode configurations. Blind seam trials in orthogonal directions revealed minimal geometric deviations, verifying the directional independence of the process, which is a major advantage over conventional processes. The integration of an ohmic preheating unit enabled stable wire feeding at high speeds and significantly reduced eccentricities of the weld bead. Compared to the cold-wire TIG-process, the hot-wire process exhibited a broader process window and higher productivity, with deposition rates exceeding 1 kg h −1 and seam height deviations consistently below 1 mm. These findings highlight the capability of the developed process to enable geometrically consistent, directionally independent, and high-efficiency layer buildup, providing a robust foundation for further development of wire-based additive manufacturing using TIG technology. TIG-DE TIG-HW DED-Arc AM Full Text Cite Share Download PDF Status: Under Review Version 1 posted Reviewers agreed at journal 30 Sep, 2025 Reviewers invited by journal 30 Sep, 2025 Editor invited by journal 29 Sep, 2025 Editor assigned by journal 25 Sep, 2025 First submitted to journal 23 Sep, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-7618430","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":522693300,"identity":"aaf7960b-fc70-45f7-9fe7-bd134119fcbb","order_by":0,"name":"Paul 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