Additive manufacturing (AM) techniques enable the production of near-net shape parts.
Wire-arc direct energy deposition (WA-DED) can achieve a higher deposition rate among other
available metal AM methods. Conventional arc welding requires a maximum interpass
temperature to limit any reduction in mechanical properties, but this may not be practicable for
wWA-DED. In this study, two interpass process control methods, one with maximum interpass
surface temperature and the other with constant dwell time, were adopted to deposit low alloyed
steel walls while maintaining the same feedstock and heat input values. Thermocouples were
inserted at three different positions in the walls during deposition, to record the thermal
profiles. Test samples extracted from walls exhibited similar tensile strength (~10 MPa
difference) and hardness values. Microstructural evaluation showed the presence of interlayer
regions with alternating coarse and fine bands of ferrite grains, irrespective of the interpass
control method. These findings suggest that dwell time control is better for productivity.Mechanical Engineerin
