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About this Abstract
Meeting 2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
Symposium 2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
Presentation Title Mechanical and Microstructural Effects of Interlayer Machining on Hybrid Wire Arc Additive Manufacturing-Processed Aluminum
Author(s) Ryan Graham Smith, Jonathan Torres, Jacob Aljundi, Aditya Pulipaka
On-Site Speaker (Planned) Ryan Graham Smith
Abstract Scope Hybrid Wire Arc-Additive Manufacturing (hWAAM) couples one or more manufacturing processes with Wire Arc-Additive Manufacturing (WAAM) to improve part quality, functionality, or efficiency. When integrated with a CNC machine, hWAAM is capable of subtractive machining operations between deposited layers. The addition of interlayer machining (ILM) introduces new variables to the deposition process, such as chip load, material removal amounts, and machining frequency, which are not well explored in relation to their effect on material properties. This study focuses on the effects of ILM on thin wall aluminum ER5556 deposited material. Mechanical properties of deposited material with varied ILM parameters will be compared through sub-scale tensile testing. Variations in microstructural features including grain size, orientation, and phase distribution will be analyzed through Scanning Electron Microscopy (SEM) and optical microscopy, and effects on porosity will be determined through X-ray Computed Tomography (XCT) scanning.
Proceedings Inclusion? Planned: Post-meeting proceedings

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Thermal Modeling of Drop Placement Strategies for Multi-Nozzle Molten Metal Jetting
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Towards Field Driven Design of Cellular Materials for Energy Absorption: Modeling and Simulation of Variable-Thickness Schwarz-P TPMS Structures
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Wire-Arc Additive Manufacturing Process Development for Martensitic Stainless Steels
Wire Arc Additive Manufacturing of Functionally Graded Materials
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Working Curve Model to Enable Precise Curing of Functionally Graded Resin Systems
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