Journal of Applied Science and Engineering

Published by Tamkang University Press

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Influences Of Process Parameters On Twin Tungsten Electrode – Wire Electrode Indirect Arc Additive Manufacturing Process

 2026

 Volume 32

Yanli Zhu1, Hong He2, Dianguo Ma1, Haibo Liu1, Peimin Li1, and Lincai Zhang1

1School of Mechanical and Electrical Engineering, Zaozhuang University, Zaozhuang, 277160, China

2Tengzhou Wanbao Stroller Co., Ltd., Tengzhou, 277500, China

Received: March 4, 2026
Accepted: April 21, 2026
Publication Date: May 17, 2026

上傳圖片

Schematic diagram of TTWIA additive manufacturing and signal and image acquisition system. 

 Copyright The Author(s). This is an open access article distributed under the terms of the Creative Commons Attribution License (CC BY 4.0), which permits unrestricted use, distribution, and reproduction in any medium, provided the original author and source are cited.

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In this paper, the effects of wire-tungsten ( d1 ) and tungsten-tungsten ( d2 ) spacing on the forming characteristic of twin tungsten electrode- wire electrode indirect arc (TTWIA) additive manufacturing were comprehensively studied. The arc shape, droplet transfer, and molten pool behavior were recorded respectively. Results showed that as d1 or d2 increased, the arc shape of TTWIA diverged and the coupling intensity was weakened. Besides,
the liquid stream became thick as well as the larger droplet diameter and lower transfer frequency, mainly attributed to the reduced arc current density and detachment forces acting on the droplet. Additionally, on account of the decreased arc pressure and droplet impingement force on the molten pool, the transverse flow tendency of liquid metal was diminished, and the molten pool width of TTWIA decreased, which was adverse to the spreading of the deposited layer. Moreover, the forming quality of the thin-walled part deteriorated, together with the increased surface roughness and reduced material utilization rate, which mainly attributed to the instability of the molten pool because of the lowered normal reaction acting on the molten pool of the present deposited layer.

Keywords: TTWIA; Wire and arc additive manufacturing; Forming characteristic; Process parameter; Arc shape

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