Wire arc additive manufacturing (WAAM) is an economical and efficient technology for manufacturing large metal parts with complex physical states that are difficult to observe in situ. However, in-depth systematic research on the fluid flow state and droplet transition behavior in WAAM under complex paths is lacking. Firstly, the free surface of the molten pool was tracked using the volume-of-fluid (VOF) method. Subsequently, by integrating matrix transformation methods, the dual ellipsoidal heat source was varied over time, and its dynamic effects on the molten pool were studied. Finally, the shapes and sizes of the deposited bead and weld pool were determined. The results showed that the droplets brought heat and kinetic energy to the molten pool and that the kinetic energy of the molten pool was more easily dissipated on complex paths than on straight paths. The impact of droplets on the molten pool, creating a negative pressure, is one of the reasons for the precipitation of gas and the eventual formation of a unique bubble distribution. The primary reason for the tilt of the molten pool in the moving direction was the influence of the liquid tension and arc pressure. The simulated profiles of the deposited bead and droplet transfer are validated using experimental cross-sectional and high-speed camera images. The consistency between the simulation results and the experimental outcomes was good, aiding the precise control of specific requirements in future production.
The full text can be downloaded at https://doi.org/10.1007/s40436-025-00559-8
Mao-Yuan Zhang
,
Yong-Hong Liu
,
Long-Fei Li
,
Chi Ma
,
Run-Sheng Li
,
Xin-Lei Wu
,
Yi-Bao Chen
,
Li-Xin Wang
,
Ren-Peng Bian
,
Zhen-Ye Su
,
Fan-Bo Meng
. Study on arc behavior and droplet transfer mechanisms under complex paths[J]. Advances in Manufacturing, 2026
, 14(1)
: 172
-188
.
DOI: 10.1007/s40436-025-00559-8
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