Optimization of weld bead start-end zones in WAAM of AA1050

Metal Additive Manufacturing (MAM) has recently expanded, offering novel possibilities in design flexibility and production efficiency through sequential layer deposition. Among MAM processes, Wire Arc Additive Manufacturing (WAAM) is widely adopted. Despite its advantages, optimizing welding parameters remains challenging, particularly in controlling bead geometry and preventing initial wall deformations at bead initiation and termination regions, where geometrical inconsistencies often occur. While some studies propose superimposing start and end regions to mitigate defects, this can introduce structural drawbacks such as insufficient fusion or cracking. This study focuses on optimizing welding parameters at bead terminations to ensure geometric continuity and uniform, defect-free walls using aluminum alloy 1050A. Using a Design of Experiments approach, arc ignition and extinction zones were optimized and experimentally validated, confirming improved bead geometry at weld extremities.