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Article

Structural Integrity Assessment of Stainless Steel Fabricated by GMAW-Assisted Wire Arc Additive Manufacturing

1
Department of Mechanical and Industrial Engineering, Rochester Institute of Technology–Dubai, Dubai P.O. Box 341055, United Arab Emirates
2
Materials and Advanced Manufacturing Research Center (MAMRC), Rochester Institute of Technology–Dubai, Dubai P.O. Box 341055, United Arab Emirates
*
Author to whom correspondence should be addressed.
Technologies 2025, 13(9), 392; https://doi.org/10.3390/technologies13090392 (registering DOI)
Submission received: 25 July 2025 / Revised: 23 August 2025 / Accepted: 27 August 2025 / Published: 1 September 2025

Abstract

Metal additive manufacturing techniques have seen technological advancements in recent years, fueled by their ability to provide industrial use parts with excellent mechanical properties. Wire Arc Additive Manufacturing is a technology that is being widely used in critical industries, and much research is conducted in this field due to the multiple factors involved in the overall process. Within WAAM, gas metal arc welding stands out for its low cost, high production volume, high quality and capability for automation. In this study, a CNC router was retrofitted with a gas metal arc welding setup to facilitate precise metal printing. The flexibility in this process allows for rapid repairs on site without the need to replace the entire part. The literature predominantly focuses on the macro-mechanical properties of GMAW parts, and very few studies try to study the interaction and influence of different process parameters on the mechanical properties. Thus, this study focused on the GMAW WAAM of stainless-steel parts by studying the influence of the wire feed rate, arc voltage and strain rate on the UTS, yield strength, toughness and percentage elongation. ANOVA and interaction plots were analyzed to study the interaction between the input parameters on each output parameter. Results showed that printing stainless steel through the gas metal arc welding process with an arc voltage of 18.7 V and a wire feed rate of 6 m/min resulted in poor mechanical properties. The input parameter that influenced the mechanical properties the highest was the wire feed rate, followed by the arc voltage and strain rate. Printing with an arc voltage of 18.7 V and a wire feed rate of 5 m/min, tested at a crosshead speed of 1 mm/min, gave the best mechanical properties.
Keywords: gas metal arc welding; analysis of variance; wire arc additive manufacturing; stainless steel gas metal arc welding; analysis of variance; wire arc additive manufacturing; stainless steel

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MDPI and ACS Style

John, J.S.; Pervaiz, S. Structural Integrity Assessment of Stainless Steel Fabricated by GMAW-Assisted Wire Arc Additive Manufacturing. Technologies 2025, 13, 392. https://doi.org/10.3390/technologies13090392

AMA Style

John JS, Pervaiz S. Structural Integrity Assessment of Stainless Steel Fabricated by GMAW-Assisted Wire Arc Additive Manufacturing. Technologies. 2025; 13(9):392. https://doi.org/10.3390/technologies13090392

Chicago/Turabian Style

John, Joel Sam, and Salman Pervaiz. 2025. "Structural Integrity Assessment of Stainless Steel Fabricated by GMAW-Assisted Wire Arc Additive Manufacturing" Technologies 13, no. 9: 392. https://doi.org/10.3390/technologies13090392

APA Style

John, J. S., & Pervaiz, S. (2025). Structural Integrity Assessment of Stainless Steel Fabricated by GMAW-Assisted Wire Arc Additive Manufacturing. Technologies, 13(9), 392. https://doi.org/10.3390/technologies13090392

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