To make metallic parts for manufacturing industries, additive manufacturing (AM) has acquired considerable significance. However, most efforts have concentrated on powder-based techniques, and there remains a dearth of the experimental evidence on the mechanical characteristics and structural behavior of metallic elements produced using wire-and-arc additive manufacturing (WAAM). This article examined the optimal parameters to enable bulk fabrication of thick walls made with a SS410 wire. The objective was to assess the optimized variables utilizing response surface methodology (RSM), followed by the microstructural analysis and mechanical property evaluation. During optimization, the influence of wire feed speed, travel speed, and gas flow rate on bead width and height was determined. Further, the optimized variables resulted in the successful formation of thick walls. Secondly, the microstructural analysis mainly featured the martensite and delta ferrite, with the latter’s percentage increasing with build height. The maximum micro-hardness of 452 HV was obtained at the base of the wall. In addition, the remarkable increases in the standard deviation of micro-hardness represent the great extent of anisotropy in the thick wall. Moreover, the maximum UTS (803 ± 8 MPa) and YS (659 ± 10 MPa) are achieved for the OB sample, which is similar to conventional components. However, the current investigation’s percentage elongation of 5% (max) demands more study before the actual use of the WAAM manufactured SS410 material. Therefore, due to the significant degree of anisotropy and poor percentage elongation, the findings conclude that post-processing is required after bulk SS410 manufacturing.

A new instrument in the production toolbox called additive manufacturing has reached the pinnacle of the most recent wave of product innovations. Chuck Hull, the founding partner of 3D Systems, first recognised the technology in 1987, which required lightweight components as feedstock for manufacturing. Nevertheless, the EOS debuted the first additive manufacturing system that utilised direct metal laser sintering (EOSINT M160) in the marketplace. 3D printers have become widely used across a variety of sectors due to the benefits they provide, especially the ability to produce intricate parts and cut down on the steps involved in the creation of products. As a consequence, several groups have jointly commercialised variations of additive manufacturing methods under their own trademarks. Under the introduction part, there is an overview of the definition of additive manufacturing technology. The basic procedures and crucial elements related to the additive manufacturing process are clarified in the following parts. Additionally, the focus is placed on the additive manufacturing processes used for making metal, plastics, and alloys. The viewer is finally exposed to the wide range of uses for additive manufacturing in the industrial sectors like aerospace, biomedicine, automobile, etc. In essence, the intent of this chapter is to inform the reader about additive manufacturing technology, including its background, core procedures, processing methods, and applications. <!----> <!----> <!----> <!---->