Anish Kumar,
- Assistant Professor, Department of Mechanical engineering, BIT, Sindri, Jharkhand, India
Abstract
Bulk metal additive manufacturing using wire-arc processes has gained significant attention for fabricating large-scale engineering components due to their high deposition rate and material efficiency. In this study, the feasibility and performance of robotic transverse twin-wire gas metal arc welding (GMAW) for bulk wire-arc additive manufacturing (WAAM) is systematically assessed. The research focuses on understanding arc stability, weld bead characteristics, and process–product relationships under high-deposition conditions. Welding current signals from both primary and secondary electrodes are analyzed to evaluate arc interactions and stability, while the influence of torch orientation and process parameters on bead geometry, penetration, and heat-affected zone characteristics is examined. Experimental investigations reveal that transverse twin-wire configuration improves arc stability and enables wider, more uniform weld beads compared to conventional tandem arrangements, making it suitable for additive manufacturing applications. An asymmetric weld bead model is developed and validated to predict bead geometry and overlapping behavior, which is critical for achieving dimensional accuracy in multi-pass, multi-layer deposition. The integration of process models with component-level design demonstrates improved material utilization and reduced post- machining requirements. The outcomes of this work establish robotic transverse twin-wire GMAW as a viable and efficient approach for large-scale WAAM, offering enhanced control over deposition quality and mechanical consistency.
Keywords: Wire-arc additive manufacturing, twin-wire GMAW, robotic welding, bulk additive manufacturing, arc stability, weld bead modeling
[This article belongs to International Journal of Robotics and Automation in Mechanics ]
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| Volume | 04 | |
| Issue | 01 | |
| Received | 26/02/2026 | |
| Accepted | 27/02/2026 | |
| Published | 14/03/2026 | |
| Publication Time | 16 Days |