Effect of Varying Layer Thickness by Interlayer Machining on Microstructure and Mechanical Properties in Wire Arc Additive Manufacturing

This study focuses on how varying layer thickness by interlayer machining affects microstructure refinement, mechanical properties, and residual stresses of Wire Arc Additive Manufacturing (WAAM) components. It compares four types of WAAM samples: As built with uneven layer thickness without interlayer machining and uniform layer thicknesses of 2mm, 1.5mm, and 1mm achieved through interlayer machining. It reveals that the machining force reduces grain size and residual stress in WAAM components. Moreover, uniform and smaller layer thickness enhances inter-layer bonding, improving mechanical properties but increases the build time with more layers of deposition.