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Meeting 2026 TMS Annual Meeting & Exhibition
Symposium Additive Manufacturing Modeling, Simulation and Artificial Intelligence
Presentation Title Simulating CMT Additive Manufacturing with CFD for Process Parameter Optimization
Author(s) Farah Kandalaft, Ozan Ozdemir
On-Site Speaker (Planned) Farah Kandalaft
Abstract Scope Wire Arc Additive Manufacturing (WAAM) enables efficient, large-scale part production. However, optimizing process parameters like gas flow rate, weld speed, and wire feed rate is essential to minimize defects like porosity and humping, which impact part quality and mechanical properties. To address these challenges and ease the optimization of these complex physical phenomena, this research focuses on the development of a computational fluid dynamics (CFD) model to simulate the Cold Metal Transfer (CMT)-WAAM process. CFD can capture critical physical phenomena including weld pool behavior, shielding gas flow dynamics, and plasma arc formation by incorporating data from other simulations and/or experiments. This approach is expected to uncover the mechanisms behind defect formation and conduct parametric studies to optimize process variables. The validation efforts conducted against experimental data is targeted to strengthen the model’s predictive capabilities to make it a powerful tool for optimizing CMT-WAAM processes and guiding future process development.
Proceedings Inclusion? Planned:
Keywords Additive Manufacturing, Modeling and Simulation,

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A Statistics-Informed Efficient Micromechanical Model for Additively Manufactured Ti-6Al-4V
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Columnar-To-Equiaxed Transition in Laser Fusion Additive Manufacturing
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F-22: An Artificial Neural Network Modeling Approach to Electroforming of Micro-Tubes in the Presence of Surfactants
F-23: Computational Thermodynamics-Based Optimization of Ti-6Al-4V via Al and V Substitution for Additive Manufacturing
F-24: Convolution Tensor Decomposition Method for Efficient High-Resolution Solutions to the Allen-Cahn Equation: Application to Grain Growth Simulations in Additive Manufacturing
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F-28: Experimental‑CFD-Based Observation of Thermo‑Fluid Mechanisms in LPBF with Nanoparticle‑Coated Powders
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F-30: Influence of Inoculants on Aluminum Alloy Microstructure Evolution During Fast Solidification: A Computational Approach Under Laser Powder Bed Fusion Conditions
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