Impact of stickout length on thermal input and material deposition in wire arc additive manufacturing of titanium

Wire Arc Additive Manufacturing (WAAM) has emerged as a viable technique for fabricating high-performance components, especially with materials like titanium. One critical parameter influencing the process efficiency and quality is the stickout length. This study investigates the impact of varying the stickout on the energy input during WAAM of titanium. By increasing the stickout length, the Joule heating effect on the wire is augmented, which potentially reduces the required arc power for achieving consistent material deposition. The research examines how adjusting the stickout length affects the thermal input to the wire and the substrate, thereby enabling optimization of the energy distribution. The results indicate that with a greater stickout, it is possible to either decrease the arc power while maintaining the deposition rate or to modulate the energy imparted to the wire and the substrate. These findings provide insights into  enhancing WAAM process efficiency and tailoring thermal profiles for improved material properties.