Repurposing welding waste stubs and wires as substrate in directed energy deposition processes

This work aims to promote alternate substrate designs in directed energy deposition (DED) processes utilising waste welding stubs and wires obtained from shielded metal arc welding (SMAW) and other arc welding processes. This is required for ease of part removal by overcoming strong fusion between the conventional bulky substrate and deposited part. The reuse of welding wastes is envisioned to reduce the environmental impact significantly. Welding stubs and wires are machined into small units and assembled together to form the deposition surface. They can be disintegrated easily to release the part, which makes the post-processing trouble-free. Aside from the stubs and wire scraps, Lego-like blocks could also be used as the small metallic units. Experimental investigation shows the formed surfaces are viable for uniform and continuous deposition, with minimal material leakage (390–730 μm depth) in voids and little dilution. A novel prototype plate concept is also introduced and demonstrated to fabricate overhanging and non-planar features. •Welding stubs have been reused to reduce welding waste.•Metal additive manufacturing shows the scope of material reuse as substrate.•Small pieces of stubs and metal scrap wires are used to design the substrate.•These substrates are easier to disintegrate and promote the ease of part removal.•Complex parts deposition with overhanging features is shown on these substrates.