Enhancement of Additive Manufacturing Processes for Thin-Walled Part Production Using Gas Metal Arc Welding (GMAW) with Wavelet Transform

Additive manufacturing encompasses technologies that produce three-dimensional computer-aided design (CAD) models through a layer-by-layer production process. Compared to traditional manufacturing methods, additive manufacturing technologies offer significant advantages in producing intricate components with minimal energy consumption, reduced raw material waste, and shortened production timelines. AM methods based on shielded gas welding have recently piqued the interest of researchers due to their high efficiency and cost-effectiveness in manufacturing critical components. However, one of the most formidable challenges in additive manufacturing methods based on shielded gas welding lies in the irregularity of weld bead height at different points, compromising the precision of components produced using these techniques. In this current research, we aimed to achieve uniform weld heights along the welding path by considering the most influential parameters on weld bead geometry and conducting experimental tests. Input parameters of the process, including nozzle angle, welding speed, wire speed, and voltage, were considered. Simultaneously, image processing and wavelet transform were employed to assess the uniformity of weld bead height. These parameters were applied to produce intricate parts after identifying optimal parameters that yielded the smoothest weld lines. According to the results, the appropriate bead for manufacturing the part was extracted. The results show that the smoothest bead line is achieved in 27 V as the highest level of voltage, at a 90° nozzle position and the maximum wire feed rate. Parts manufactured using this method across different layers exhibited no distortions, and the repeatability of production substantiated the high reliability of this approach for component manufacturing.