Enhancing the strength and ductility of 316 L cladding via dual-pulse wire arc additive manufacturing process control

This paper utilizes an advanced dual-pulse wire arc additive manufacturing (DP-WAAM) method, which employs heat management strategies by controlling two key parameters: dual-pulse frequency (f) and duty cycle (Dt). The approach aims to enhance the strength and ductility of 316 L claddings. An investigation is conducted into the effects of different parameters on arc morphology, deposition geometry, microstructure, and their interrelated properties. The results demonstrate that by regulating f and Dt to achieve a low heat input effect, the new method effectively manages heat conditions, leading to improved strength and ductility of the deposits without increasing manufacturing cost and complexity. Under the f = 4 Hz and Dt = 60 %, the hardness of the deposited sample increased by approximately 22 % (from 179 HV0.1 to 217.1 ± 2.5 HV0.1), while the tensile strength increased by about 19 % (from 536 ± 4 MPa to 636 ± 6 MPa). Additionally, when Dt = 60 % and f ≥ 3 Hz, the dilution rate is generally within or close to the optimal range, and the left and right wetting angles range from 30° to 55°, with a difference of less than 5°. This indicates a stable deposition process, resulting in a uniform and reliable part morphology. Hence, this study offers a direct strategy for optimizing metal material formation and enhancing performance in additive manufacturing technology. [Display omitted] •Employing an advanced DP-WAAM for heat management and property control.•First measurement of the difference between the left and right wetting angles.•Simultaneous strength and ductility enhancement via heat management.•Optimal deposition conditions for uniform, high-quality component morphology.