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Doctoral Thesis
Author of thesis: Ing. Jakub Slavíček, Ph.D.
Acad. year: 2025/2026
Supervisor: doc. Ing. Daniel Koutný, Ph.D.
Reviewers: Assoc. Prof. Dr. Damjan Klobčar, Dr. Stephan Anton Ucsnik
Wire arc directed energy deposition (WADED) represents a promising additive manufacturing technology for the fabrication of large-scale lightweight structural components. This potential arises from the low density of magnesium alloys combined with their high strength-to-weight ratio. However, their processing by arc-based additive manufacturing remains challenging due to their high chemical reactivity, thermal sensitivity, and susceptibility to defect formation. A limited understanding of deposition strategies, process stability, and thermal management has restricted the wider application of WADED for magnesium alloys. This dissertation focuses on WADED processing of the AZ61 magnesium alloy to improve geometrical accuracy, process stability, and material microstructural while mitigating residual stresses. The research systematically investigates the influence of deposition path planning, cold metal transfer (CMT) characteristic parameters, and thermal management strategies on bead geometry, microstructural evolution, and residual stress development. Particular attention is paid to characteristic structural features, including thin walls, overhangs, and volumetric components. The results demonstrate that appropriate path-planning strategies can significantly reduce geometric deviations in thin walls and volumetric components. Furthermore, the study shows that individual CMT characteristic parameters strongly influence metal transfer behaviour and process stability, highlighting the need for their systematic optimisation. Thermal management strategies, including preheating and interpass temperature control, are shown to reduce residual stresses while simultaneously promoting grain coarsening. Therefore, it is necessary to identify an optimal compromise between microstructural refinement and residual stress reduction. The outcomes of this work contribute to a deeper understanding of WADED processing of AZ magnesium alloys and provide practical guidelines for improving process robustness and component quality. The findings support the broader application of WADED for magnesium alloy structural parts and establish a foundation for future development of arc-based additive manufacturing of lightweight materials.
Wire arc directed energy deposition (WADED or WAAM), magnesium alloys, wire arc additive manufacturing, thin walls, overhangs, volumetric parts, deposition strategies, process parameters, residual stresses, microstructure, porosity, mechanical properties
Date of defence
21.07.2026
Result of the defence
Defended (thesis was successfully defended)
Process of defence
The dissertation meets the requirements arising from Section 47 of Act No. 111/1998 Coll., on Higher Educations Institutions and on Amendments and Supplements to Other Acts, and from Article 40 of the Study and Examination Regulations of BUT. It contains original results published, among others, in four articles in an impact-factor journal.
Language of thesis
English
Faculty
Fakulta strojního inženýrství
Department
Institute of Machine and Industrial Design
Study programme
Design and Process Engineering (D-KPI-P)
Composition of Committee
prof. Ing. Martin Hartl, Ph.D. (předseda) doc. Ing. Milan Omasta, Ph.D. (místopředseda) doc. RNDr. Libor Mrňa, Ph.D. (člen) Assoc. Prof. Dr. Damjan Klobčar (člen) Dr. Stephan Anton Ucsnik (člen)
Supervisor’s reportdoc. Ing. Daniel Koutný, Ph.D.
Grade proposed by supervisor: A
Reviewer’s reportAssoc. Prof. Dr. Damjan Klobčar
Reviewer’s reportDr. Stephan Anton Ucsnik
Responsibility: Mgr. et Mgr. Hana Odstrčilová