Process Optimization and Mechanical Characterization of Stainless Steel 312 Alloy Components Fabricated by Wire Arc Additive Manufacturing

Abstract—Wire Arc Additive Manufacturing (WAAM) is an emerging metal additive manufacturing technique offering high deposition rates and cost-effective production for large-scale metal components. This study employs WAAM to fabricate Stainless Steel 312 (SS312) components and systematically investigates the influence of key process parameters—wire feed speed, travel speed, arc current, and interpass temperature—on mechanical and microstructural outcomes. A Design of Experiments (DoE) approach identifies the optimal parameter combinations that minimize defects such as porosity, cracking, and lack of fusion. Mechanical characterization encompasses tensile testing, yield strength measurement, elongation analysis, and microstructural examination via Scanning Electron Microscopy (SEM). Results demonstrate that optimized WAAM parameters yield a uniform duplex microstructure, reduced internal defects, and mechanical properties comparable to wrought SS312, confirming WAAM as a viable manufacturing route for high-performance components in aerospace, marine, and energy applications.