Clamping Strategy for Single-Layer Wire Arc Additive Manufacturing Using Gas Metal Arc Welding of the AA6061 Substrate and ER5356 Filler

DOI

10.2991/978-94-6239-717-0_16How to use a DOI?

Keywords

AA6061; Clamping; ER5356; GMAW; WAAM

Abstract

Wire Arc Additive Manufacturing is a Direct Energy Deposition process that uses an electric arc as the heat source to melt metal wire layer by layer. WAAM-based additive manufacturing presents one of its main challenges: material deformation caused by thermal effects during the welding process. In this study, the materials used were AA6061 as the substrate and ER5356 as the filler. The novelty of this research lies in its analysis of clamping configurations as a primary variable for controlling distortion during the WAAM of aluminum. This approach yields significant benefits in cost reduction, product quality enhancement, and time efficiency. This research aims to determine the most effective method for evaluating, both experimentally and numerically, the effect of different substrate clamping strategies on distortion and residual stress in the WAAM process. The experimental results show that the maximum temperature recorded by the thermal gun reached 828°C in Strategy 2. In contrast, the simulations showed a peak temperature of 912°C. The simulation results also indicated that the highest Von Mises stress occurred in strategy 4 is the one with the highest residual stress among the others, reaching 59.62 MPa. Both the experimental and simulation results for Strategy 8 showed the smallest deflection in the substrate area, with a maximum difference of only 0.20 mm in the experiment and 0.13 mm in the simulation at certain points. The low deflection in Strategy 8 suggests that the number and positioning of clamps during the WAAM process have a significant impact on reducing substrate deflection.

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  - Afrizal Riyantono
AU  - Agus Sifa
AU  - Faza Khoirina
AU  - Agus Sentana
AU  - Ario Sunar Baskoro
AU  - Gandjar Kiswanto
PY  - 2026
DA  - 2026/06/25
TI  - Clamping Strategy for Single-Layer Wire Arc Additive Manufacturing Using Gas Metal Arc Welding of the AA6061 Substrate and ER5356 Filler
BT  - Proceedings of the 19th International Conference on Quality in Research (QiR 2025)
PB  - Atlantis Press
SP  - 215
EP  - 230
SN  - 2352-5401
UR  - https://doi.org/10.2991/978-94-6239-717-0_16
DO  - 10.2991/978-94-6239-717-0_16
ID  - Riyantono2026
ER  -