Effect of Interpass Temperature in the Single-Layer ER5356 WAAM-GMAW Milling Process on Tool Wear and Surface Roughness

DOI

10.2991/978-94-6239-717-0_15How to use a DOI?

Keywords

ER5356; GMAW-Milling; Hybrid-WAAM; Roughness; Tool Wear

Abstract

The application of additive manufacturing (AM) techniques is crucial to developing the industrial sector. This method is demonstrated by the use of wire-based methods to achieve effective and efficient production results. Wire arc additive manufacturing (WAAM) is a type of additive manufacturing process that relies on melting metal through an electric arc, allowing metal wires to be arranged to form the desired component gradually. The WAAM process generates residual heat, which must be considered in subsequent post-processing stages, particularly when using milling process. In this study, the WAAM process employed the gas metal arc welding (GMAW) method, using an AA6061 aluminum series substrate and ER5356 filler material. The research applied the Johnson-Cook method and conducted experiments at interpass temperatures of 100°C, 150°C, and 200°C to investigate the effects of the WAAM-GMAW process on tool wear and surface roughness at specific interpass temperatures during milling process. The methodology involved milling process modeling with a cutting depth of 0.3 mm, as well as experiments to measure cutting stress, tool wear, and surface roughness quality. The results showed a change in tool diameter after the milling process, from 10.654 mm to 9.824 mm. At a weld bead temperature of 200°C, the shortest cooling time was observed, which contributed to minimizing tool wear. However, the surface roughness of the weld bead was high, measured at 1.732 μm. This result was caused by the elevated temperature of the weld bead, which reduced hardness, induced oxidation and diffusion, resulting in unstable cutting and increased surface roughness.

Copyright

© 2026 The Author(s)

Open Access

Open Access This chapter is licensed under the terms of the Creative Commons Attribution-NonCommercial 4.0 International License (http://creativecommons.org/licenses/by-nc/4.0/), which permits any noncommercial use, sharing, adaptation, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license and indicate if changes were made.

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TY  - CONF
AU  - Faza Khoirina
AU  - Afrizal Riyantono
AU  - Agus Sifa
AU  - Agus Sentana
AU  - Ario Sunar Baskoro
AU  - Gandjar Kiswanto
PY  - 2026
DA  - 2026/06/25
TI  - Effect of Interpass Temperature in the Single-Layer ER5356 WAAM-GMAW Milling Process on Tool Wear and Surface Roughness
BT  - Proceedings of the 19th International Conference on Quality in Research (QiR 2025)
PB  - Atlantis Press
SP  - 199
EP  - 214
SN  - 2352-5401
UR  - https://doi.org/10.2991/978-94-6239-717-0_15
DO  - 10.2991/978-94-6239-717-0_15
ID  - Khoirina2026
ER  -