Abstract

Wire Arc Additive Manufacturing (WAAM) has emerged as a transformative technique for producing complex metallic structures, particularly utilizing superalloys for high-performance applications in aerospace, energy, and automotive sectors. However, cracking in superalloy structures during WAAM remains a critical challenge, undermining mechanical integrity and limiting industrial adoption. This study proposes a conceptual framework for mitigating cracking in superalloy structures during the WAAM process. The framework integrates material science insights, process optimization strategies, and real-time monitoring technologies to address the underlying causes of cracking. The primary focus lies on understanding the interplay between thermal gradients, residual stresses, and alloy composition in the context of WAAM. Key strategies include optimizing deposition parameters such as current, voltage, and inter-pass temperature to minimize thermal stresses. Additionally, preheating and post-heating treatments are explored to reduce cracking susceptibility by refining microstructures and alleviating residual stresses. Advanced simulation tools are incorporated to predict cracking-prone zones by modeling thermal cycles and stress distributions. Furthermore, real-time monitoring systems, utilizing infrared thermography and acoustic emission techniques, are proposed to detect and mitigate cracking during fabrication. The integration of data-driven approaches, including machine learning algorithms, enhances predictive capabilities and facilitates adaptive process control. Experimental validation is conducted using nickel-based superalloys, evaluating the effectiveness of the proposed strategies in reducing crack density and improving structural integrity. Results demonstrate that the holistic framework significantly mitigates cracking by fostering favorable thermal and mechanical conditions. The study emphasizes the importance of multidisciplinary approaches in advancing WAAM technologies for superalloys, bridging the gap between research and industrial implementation. By addressing the critical issue of cracking, the proposed framework contributes to the development of reliable, high-performance additive manufacturing processes, paving the way for broader applications in critical industries.