This study investigates the impact of process parameters on the geometry of single-layer overlay welds of AA5087 aluminum alloy, fabricated using Wire and Arc Additive Manufacturing (WAAM-MIG), a technique valued for its productivity and material efficiency. This method layers material as weld beads to build 3D structures. Key characteristics analyzed include bead width, bead height, penetration depth, porosity, and costs related to shielding gas flow rates. Using the Taguchi method with an L27 orthogonal array, the study optimized experimental designs while reducing trial numbers. Grey relational analysis enabled the simultaneous evaluation of multiple parameters. Optimization was conducted for individual responses and through multi-objective analysis to determine the significance of parameters for each characteristic. The findings enhance understanding of the WAAM-MIG process and its application in manufacturing components with precise geometric characteristics, supporting advancements in additive manufacturing.
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