Influence of process parameters and common printing problems on tensile behaviour of DED-Arc
File(s)
Published version
Author(s)
Meng, Xin
Weber, Ben
Gardner, Leroy
Type
Journal Article
Abstract
Wire-arc directed energy deposition (DED-Arc), also known as wire arc additive manufacturing (WAAM), brings about new opportunities for construction decarbonisation and automation. Overall, the mechanical behaviour of DED-Arc steel is largely comparable to conventionally produced structural steel; however, the performance under tensile loading has been shown to be more variable and susceptible to printing defects. Therefore, an experimental study has been conducted to offer deeper insights into the tensile behaviour of DED-Arc steel elements, with a particular focus on the influence of the process parameters and the consequences of common printing problems. Two groups of DED-Arc steel members with I-section profiles were examined. The first group was designed with different wall thicknesses ranging from 3.5 to 8 mm, achieved by varying key printing parameters and toolpaths, as well as with passive or active cooling. The second group featured the same process parameters but with common printing problems intentionally introduced, including layer shifts, unstable shield gas,
wire feed issues, inclusions, lack of preheating and inconsistent stick out. The test specimens were laser scanned to examine their dimensional properties and surface texture, and then loaded to fracture under axial tension. The influence of wall thickness, toolpath and cooling method on the strength and ductility was highlighted. The common printing problems were shown to slightly deteriorate the strength but significantly reduce the ductility, with unstable shield gas and wire feed issues being the most detrimental. These findings mark a crucial step towards the safe use of DED-Arc for load-bearing applications in construction.
wire feed issues, inclusions, lack of preheating and inconsistent stick out. The test specimens were laser scanned to examine their dimensional properties and surface texture, and then loaded to fracture under axial tension. The influence of wall thickness, toolpath and cooling method on the strength and ductility was highlighted. The common printing problems were shown to slightly deteriorate the strength but significantly reduce the ductility, with unstable shield gas and wire feed issues being the most detrimental. These findings mark a crucial step towards the safe use of DED-Arc for load-bearing applications in construction.
Date Issued
2026-02-01
Date Acceptance
2025-10-12
Citation
Journal of Constructional Steel Research, 2026, 237 (Part A)
ISSN
0143-974X
Publisher
Elsevier
Journal / Book Title
Journal of Constructional Steel Research
Volume
237
Issue
Part A
Copyright Statement
© 2025 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY license (http://creativecommons.org/licenses/by/4.0/).
License URL
Publication Status
Published
Article Number
110053
Date Publish Online
2025-11-08