Parameter Selection Strategies for High-Performance WAAM Structures in Automotive Engineering

Wire Arc Additive Manufacturing (WAAM) has gained traction as an advanced fabrication technique for producing large, structurally demanding components in the automotive industry. Achieving high-performance WAAM structures requires precise control and selection of key process parameters, which directly influence mechanical strength, dimensional accuracy, and surface quality. This study investigates the effect of critical process variables—including wire feed rate, travel speed, current, voltage, and inter-layer cooling time—on the structural integrity of WAAM-fabricated components designed for automotive use. A systematic experimental approach, supported by statistical modeling and optimization tools, was employed to identify parameter combinations that yield optimal results. The outcomes demonstrate improved microstructural uniformity, reduced residual stresses, and enhanced tensile properties in the fabricated parts. The findings serve as a foundation for developing robust parameter selection strategies aimed at integrating WAAM into high-performance automotive manufacturing workflows.