LAUSR

Abstract The problem of deposition accuracy is encountered during gas tungsten arc welding (GTAW) based additive manufacturing when wire is fed in side direction. A mathematical model was developed to calculate the wire flying distance in arc zone, according to which displacement compensation was designed to ensure the size accuracy. When arc length was 5 mm and vertical distance of wire tip to tungsten electrode was larger than 3 mm, the horizontal distance between melting wire tip and axis of tungsten electrode was 3.5 mm. The displacement compensation was verified to be effective by forming cross-angle. The model can also be used to achieve bridging transfer, which is beneficial for smooth layer appearance.