The effect of atmosphere on the composition of wire arc additive manufactured metal components

The effects of atmospheric contamination on wire arc additively manufactured (WAAM) components were studied by producing AM multilayer parts under controlled conditions. Gas impurity levels were maintained using an argon purge box at levels from atmospheric (210,000 ppm O-2) to 1 ppm O-2, and with corresponding levels of nitrogen. Stainless steel (308L), titanium (Ti-6Al-4V) and pure Ta were studied, each having different affinities for oxygen and nitrogen. Results show that WAAM parts made in air produce unacceptable oxygen and/or nitrogen levels for most applications. However, with moderate purging, all three metals can be deposited by WAAM with compositions similar to the starting wire, and the results are used to provide recommended minimum purge box atmospheres for each metal.