Modeling and optimization of height-related geometrical parameters for thin wall structures manufactured by metal additive manufacturing

Modeling and optimization of height-related geometrical parameters for thin wall structures manufactured by metal additive manufacturing | 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 Modeling and optimization of height-related geometrical parameters for thin wall structures manufactured by metal additive manufacturing Mostafa Rahmani Dehaghani, Yifan Tang, Suraj Panicker, Di Wu, and 2 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-3211157/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 09 Nov, 2023 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted 5 You are reading this latest preprint version Abstract Cold metal transfer wire arc additive manufacturing (CMT-WAAM) has attracted attention in recent years due to its ability to print walls with higher dimensional accuracy than regular WAAM. To print near net shape parts by CMT-WAAM, there is a need to define a set of height-related geometrical parameters (HGPs) that can capture, quantify, and compare the quality of the height of the produced parts. In the presenting study a set of HGPs, namely, the average height error (AHE), maximum height variation (MHV), and average absolute slope (AAS) are defined and assessed. Fifteen single-track multi-layer walls are printed to check the effect of process parameters on the defined HGPs. It is found that the stability and quality of the print cannot be guaranteed by checking the visual appearance of the single beads and at least five-to-ten-layer walls should be printed. It is also found that the travel speed (TS) and wire feed speed (WFS) have positive monotonic relationships with AAS and MHV, respectively. Correlations between process parameters and HGPs are modeled and optimized using multi-objective optimization and a validation test is performed to check the validity of the developed models. Moreover, HGPs of walls printed using unidirectional and bidirectional path strategies are calculated and compared. Defined HGPs are able to quantify, capture, and compare the quality of height of a wall with only three parameters. The HGPs can be used in further studies to report and compare the quality of height of thin wall structures. cold metal transfer wire arc additive manufacturing geometrical deviation multi-objective optimization Full Text Cite Share Download PDF Status: Published Journal Publication published 09 Nov, 2023 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted Editorial decision: Minor Revisions Needed 12 Oct, 2023 Reviewers agreed at journal 23 Aug, 2023 Reviewers invited by journal 29 Jul, 2023 Editor assigned by journal 28 Jul, 2023 First submitted to journal 27 Jul, 2023 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. 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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-3211157","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":222531846,"identity":"e2911bab-6af2-4755-8eac-3fb3aa722e0d","order_by":0,"name":"Mostafa Rahmani Dehaghani","email":"","orcid":"","institution":"","correspondingAuthor":false,"submittingAuthor":false,"prefix":"","firstName":"Mostafa","middleName":"Rahmani","lastName":"Dehaghani","suffix":""},{"id":222531847,"identity":"b5cbfe3b-2fc6-4fad-a7b7-ebfdeff3036a","order_by":1,"name":"Yifan Tang","email":"","orcid":"","institution":"","correspondingAuthor":false,"submittingAuthor":false,"prefix":"","firstName":"Yifan","middleName":"","lastName":"Tang","suffix":""},{"id":222531848,"identity":"7c5fa4d0-1c31-4c26-960f-faca8ecf0ad8","order_by":2,"name":"Suraj Panicker","email":"","orcid":"","institution":"","correspondingAuthor":false,"submittingAuthor":false,"prefix":"","firstName":"Suraj","middleName":"","lastName":"Panicker","suffix":""},{"id":222531849,"identity":"971440ff-ad7d-4f8a-b4f5-8610d084f7b7","order_by":3,"name":"Di Wu","email":"","orcid":"","institution":"","correspondingAuthor":false,"submittingAuthor":false,"prefix":"","firstName":"Di","middleName":"","lastName":"Wu","suffix":""},{"id":222531850,"identity":"c9b012ae-5416-4f70-b9f6-0baaf098a2e3","order_by":4,"name":"Eric Coatanea","email":"","orcid":"","institution":"","correspondingAuthor":false,"submittingAuthor":false,"prefix":"","firstName":"Eric","middleName":"","lastName":"Coatanea","suffix":""},{"id":222531851,"identity":"bd8cd2ca-7960-4f97-a1ed-0b3637a92697","order_by":5,"name":"G. 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