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Volume 13 | Issue 4 | Year 2026 | Article Id. IJME-V13I4P105 | DOI : https://doi.org/10.14445/23488360/IJME-V13I4P105

Bead Morphology Optimization for FLUX Cored Wires in the Wire ARC AM of 1.14 CR-1.0 MO Steel

Vaishali Prajapati, Vyomesh Buch, Jay Vora

Received Revised Accepted Published
10 Jan 2026 20 Feb 2026 20 Mar 2026 29 Apr 2026

Citation :

Vaishali Prajapati, Vyomesh Buch, Jay Vora, "Bead Morphology Optimization for FLUX Cored Wires in the Wire ARC AM of 1.14 CR-1.0 MO Steel," International Journal of Mechanical Engineering, vol. 13, no. 4, pp. 62-77, 2026. Crossref, https://doi.org/10.14445/23488360/IJME-V13I4P105

Abstract

Wire Arc Additive Manufacturing (WAAM), which uses gas metal arc welding, is a promising approach to preparing bulky metal components. WAAM allows consecutive bead deposition for complex forms. The input parameters of the machining process determine deposition quality. The main outputs are Bead Height (BH), Penetration Depth, and Bead Width (BW). This study optimizes Wire Arc Additive Manufacturing (WAAM) parameters for improvement in bead height, Depth of penetration, and bead width. Regression models were tested for adequacy and robustness using variance statistics. Strong model fit was indicated by R² and modified R² values approaching unity and optimizing used the parameter-free metaheuristic Passing Vehicle Search (PVS) algorithm. Minimum BW was 3.58 mm, maximum BH 6.37 mm, and maximum DOP 1.24 mm were found in multi-objective optimization. The algorithm’s efficacy was shown by validation testing, showing disparities between optimized and non-optimized parameters under 5%. Multilayer metal structures were flawlessly produced using these optimal settings. The study provides reliable WAAM parameter sets for high-temperature industrial applications and serves as a baseline for future research.

Keywords

GMAW, Flux-Cored Wire, Optimization, PVS Algorithm, Wire Arc AM.

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