Wire Arc Additive Manufacturing (WAAM), one of the Additive Manufacturing (AM) deposition methods which employs the basic principles of Gas Metal Arc Welding (GMAW) welding technique was used to show that it is possible to build moulds for ceramic products using AISI 420 stainless steel due to its characteristics such as corrosion resistance, machinability, hardness and dimensional stability. The WAAM process also is efficient in terms of its deposition rate, reduced material wastage and high surface quality.

To investigate the feasibility of AM of AISI 420 stainless steel using WAAM, Response Surface Methodology (RSM - a predictive technique) was used to navigate within the input parameter range for process optimization. Bead-on-plate welding experiments were performed with a MIG welding robot on a structural steel (S355J2) as the substrate. In the tested range according to RSM analyses, the optimum weld condition was 261 A (Current), 29 V (Volts) and 0.59 m/min S (Travel Speed) with preheating at 200°C. However, this condition was found to be unsuitable for AM due to its low deposition speed, non - uniform building surface morphology and inter-run porosities when overlapping welds were deposited. Further analyses on the metallurgy of the WAAM AISI 420 stainless steel through Scanning Electron Microscope (SEM) revealed that the weld metal consisted of a martensite matrix and delta-ferrite at the grain boundaries. The Vickers Hardness of the weld metal was 514HV.

To achieve WAAM feasibility using AISI 420 stainless steel, modified RSM method was performed by expanding the input parameters and visually inspecting the bead for its shape, size and quality. The experiment adopted was called the Ramping Procedure wherein a single resulting weld bead can represent many input parameter combinations. The optimum condition for the input parameters were identified to be 200 A (Current), 18.5 V (Volts) and 1.00 m/min S (Travel Speed). With the optimal processing conditions, rectangular blocks or walls were modelled and designed in the Autodesk Powermill software and built to evaluate the feasibility of WAAM AISI 420 stainless steel. Samples were built without preheating and no surface defects and cracking were observed. Microstructural and hardness studies were then performed. Results show that the as-welded weld metal consisted of delta-ferrite present in a martensite matrix. The hardness of the weld metal was 623 HV.

The WAAM optimization procedure for AISI 420 stainless steel that has not been explored for AM processes due to its high sensitivity to welding thermal cycles that can lead to cracking. In this study, it has been successfully demonstrated that crack free AISI 420 stainless steel can be deposited with WAAM.