The investigation on the influence of key process parameters on the fabrication properties of CMT Thin-Walled Structure

The investigation on the influence of key process parameters on the fabrication properties of CMT Thin-Walled Structure | 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 The investigation on the influence of key process parameters on the fabrication properties of CMT Thin-Walled Structure Liyi Jiang, Chaoyi Shen, Yuchen Zhang, Changdong Zhang, Yixuan Xiao, and 2 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7341834/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 Wire Arc Additive Manufacturing (WAAM) has demonstrated significant potential in fabricating metal structural components due to its high efficiency and low cost. However, applying this technology to thin-walled structures remains challenging owing to two key issues: pronounced heat accumulation and poor dimensional accuracy control. To investigate the influence of process parameters on the forming quality of thin-walled structures, this study focused on four critical parameters in the cold metal transfer (CMT) process, including Travel Angle (α), Work Angle (β), Wire Feed Speed (WFS), and Travel Speed (TS). An L25 (5 4 ) orthogonal experiment was conducted to investigate the effects and correlations of these process parameters on the relative density and surface morphology of the fabricated structures. The results showed that relative density was most substantially affected by WFS. As WFS increases, the relative density of printed parts gradually decreases. At a WFS of 3 m/min, the optimal average relative density of the formed parts reached 98.69%. Under this condition the best-performing parameter combination for achieving the highest relative density was A1B1C1D2. Meanwhile, TS exhibited the greatest influence on surface morphology, followed by Work Angle. When TS was 14 mm/s and Work Angle was 0°, both interlayer roughness and intralayer roughness reached their minimum values. The optimal process parameter combination for achieving the best surface morphology was A2B1C4D2. Analysis shows that parameter combinations should be selected based on component functional requirements, as mechanisms underlying optimal relative density and surface morphology differ. Additive manufacturing Cold metal transfer Welding angle Thin-walled structures Full Text Cite Share Download PDF Status: Under Review Version 1 posted Reviewers agreed at journal 24 Sep, 2025 Reviewers invited by journal 23 Sep, 2025 Editor invited by journal 29 Aug, 2025 Editor assigned by journal 26 Aug, 2025 First submitted to journal 21 Aug, 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-7341834","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":519450502,"identity":"5fcc4cf6-d407-4ef7-8f32-6ba5ae86865b","order_by":0,"name":"Liyi 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Structure","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":false,"highlight":"","institution":"","isAcceptedByJournal":true,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":true,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"welding-in-the-world","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"witw","sideBox":"Learn more about [Welding in the World](https://www.springer.com/journal/40194)","snPcode":"40194","submissionUrl":"https://www.editorialmanager.com/witw/","title":"Welding in the World","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false},"keywords":"Additive manufacturing, Cold metal transfer, Welding angle, Thin-walled structures","lastPublishedDoi":"10.21203/rs.3.rs-7341834/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-7341834/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eWire Arc Additive Manufacturing (WAAM) has demonstrated significant potential in fabricating metal structural components due to its high efficiency and low cost. However, applying this technology to thin-walled structures remains challenging owing to two key issues: pronounced heat accumulation and poor dimensional accuracy control. To investigate the influence of process parameters on the forming quality of thin-walled structures, this study focused on four critical parameters in the cold metal transfer (CMT) process, including Travel Angle (α), Work Angle (β), Wire Feed Speed (WFS), and Travel Speed (TS). An L25 (5\u003csup\u003e4\u003c/sup\u003e) orthogonal experiment was conducted to investigate the effects and correlations of these process parameters on the relative density and surface morphology of the fabricated structures. The results showed that relative density was most substantially affected by WFS. As WFS increases, the relative density of printed parts gradually decreases. At a WFS of 3 m/min, the optimal average relative density of the formed parts reached 98.69%. Under this condition the best-performing parameter combination for achieving the highest relative density was A1B1C1D2. Meanwhile, TS exhibited the greatest influence on surface morphology, followed by Work Angle. When TS was 14 mm/s and Work Angle was 0\u0026deg;, both interlayer roughness and intralayer roughness reached their minimum values. The optimal process parameter combination for achieving the best surface morphology was A2B1C4D2. Analysis shows that parameter combinations should be selected based on component functional requirements, as mechanisms underlying optimal relative density and surface morphology differ.\u003c/p\u003e","manuscriptTitle":"The investigation on the influence of key process parameters on the fabrication properties of CMT Thin-Walled Structure","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2025-10-06 07:21:14","doi":"10.21203/rs.3.rs-7341834/v1","editorialEvents":[{"type":"communityComments","content":0},{"type":"reviewerAgreed","content":"","date":"2025-09-24T07:57:44+00:00","index":0,"fulltext":""},{"type":"reviewersInvited","content":"","date":"2025-09-23T13:59:20+00:00","index":"","fulltext":""},{"type":"editorInvited","content":"Welding in the World","date":"2025-08-29T14:42:10+00:00","index":"","fulltext":""},{"type":"editorAssigned","content":"","date":"2025-08-26T06:28:29+00:00","index":"","fulltext":""},{"type":"submitted","content":"Welding in the World","date":"2025-08-21T22:32:29+00:00","index":"","fulltext":""}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"welding-in-the-world","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"witw","sideBox":"Learn more about [Welding in the World](https://www.springer.com/journal/40194)","snPcode":"40194","submissionUrl":"https://www.editorialmanager.com/witw/","title":"Welding in the World","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false}}],"origin":"","ownerIdentity":"19b5ff49-99c6-4b08-b232-82aec57d0d73","owner":[],"postedDate":"October 6th, 2025","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"under-review","subjectAreas":[],"tags":[],"updatedAt":"2026-02-04T19:17:47+00:00","versionOfRecord":[],"versionCreatedAt":"2025-10-06 07:21:14","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-7341834","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-7341834","identity":"rs-7341834","version":["v1"]},"buildId":"XKTyCvWXoU3ODBz1xrDgd","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}