Wire Arc Additive Manufacturing is a near-net-shape processing technology which allows the cost-effective manufacturing of big and customized metal parts. In the present work the Wire Arc Additive Manufacturing of AW4043/AlSi5(wt.%) with different lead angles of the welding torch was investigated. It has been shown that for some lead angles fluctuation effects occur in the structures produced if the interlayer temperature is either too low or too high. All experiments were analysed by high-speed imaging whereby the welding phenomena could be observed. In the case of Wire Arc Additive Manufacturing with a lead angle above 10° at lower interlayer temperatures, the deposited track consists out of several, seperated WAAM globules and is no longer in a uniform track. In the case of the dragging and neutral Wire Arc Additive Manufacturing processes at higher interlayer temperatures, fluctuation effects occur. In addition, by evaluating the high-speed videos with computer vision, it was found that such fluctuation effects can be detected at the arc frequency of the process. To avoid fluctuation effects caused by too low or too high interlayer temperatures, a pushing Wire Arc Additive Manufacturing process with a slightly tilted lead angle should be used.

电弧焊增材制造是一种近净形加工技术，可以经济高效地制造大型定制金属零件。在本工作中，研究了焊枪不同导程角的AW4043 / AlSi5（wt。％）的电弧增材制造。已经表明，对于某些超前角，如果层间温度太低或太高，在所产生的结构中都会产生波动效应。所有实验均通过高速成像进行分析，从而可以观察到焊接现象。对于在较低的夹层温度下引线角大于10°的电弧增材制造，沉积的焊道由多个分离的WAAM小球组成，不再处于均匀的焊道中。在较高的夹层温度下进行拖曳和中性的“电弧电弧增材制造”过程时，会产生波动效应。另外，通过用计算机视觉评估高速视频，发现可以在过程的弧频处检测到这种波动效果。为避免因过低或过高的夹层温度而引起的波动影响，应使用引线角度略微倾斜的推丝电弧增材制造工艺。