Xiong J, Zhang Y, Pi Y (2020) Control of deposition height in WAAM using visual inspection of previous and current layers. Ortega AG, Galvan LC, Beaume FD, Mezrag B, Rouquette S (2017) Effect of process parameters on the quality of aluminium alloy Al5Si deposits in wire and arc additive manufacturing using a cold metal transfer process. Oyama K, Diplas S, M'Hamdi M, Gunnæs AE, Azar AS (2019) Heat source management in wire-arc additive manufacturing process for Al-Mg and Al-Si alloys. Köhler M, Hensel J, Dilger K (2020) Effects of thermal cycling on wire and arc additive manufacturing of Al-5356 components. Gierth M, Henckell P, Ali Y, Scholl J, Bergmann JP (2020) Wire arc additive manufacturing (WAAM) of aluminum alloy AlMg5Mn with energy-reduced gas metal arc welding (GMAW). Su C, Chen X, Gao C, Wang Y (2019) Effect of heat input on microstructure and mechanical properties of Al-Mg alloys fabricated by WAAM. Ou W, Wei Y, Liu R, Zhao W, Cai J (2020) Determination of the control points for circle and triangle route in wire arc additive manufacturing (WAAM). Ou W, Mukherjee T, Knapp GL, Wei Y, DebRoy T (2018) Fusion zone geometries, cooling rates and solidification parameters during wire arc additive manufacturing. ĭebroy T, David S (1995) Physical processes in fusion welding. Williams SW, Martina F, Addison AC, Ding J, Pardal G, Colegrove P (2016) Wire + arc additive manufacturing. Rodrigues TA, Duarte V, Miranda RM, Santos TG, Oliveira JP (2019) Current status and perspectives on wire and arc additive manufacturing (WAAM). Gao W, Zhang Y, Ramanujan D, Ramani K, Chen Y, Williams CB, Wang CCL, Shin YC, Zhang S, Zavattieri PD (2015) The status, challenges, and future of additive manufacturing in engineering. Finally, to validate the model, the deposit profiles are also compared between simulated and experimental results. In addition, the interlayer idle time contributes to the formation of deposit with higher height and narrow width. On the surface of molten pool, the liquid metal dominated by Marangoni force flows from center to periphery, and on the bottom of molten pool, a clockwise circulation is formed. The calculated results indicate that when the droplet falls into the molten pool, the maximum velocity inside the droplet reaches 0.9m/s, resulting in that liquid metal in the middle flows toward the bottom of the molten pool and a depressed region is formed. By the developed model, the simulations of single-pass multi-layer of WAAM of Al-5%Mg are performed. The processes of droplet formation, growth, and detachment from the end of wire electrode, who travels dynamically along the scanning direction, are coupled with molten pool for the first time by considering their own mechanical conditions and solving the transport equations in the whole solution domain. In this study, we develop a 3D transient mathematic model to simulate the heat transfer, fluid flow, and geometry morphology in GMAW-based wire arc additive manufacturing (WAAM).