AccScience Publishing / MSAM / Online First / DOI: 10.36922/MSAM026180035
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ORIGINAL RESEARCH ARTICLE

Environmental implications of feedback-controlled heat input in wire arc additive manufacturing of Invar 36 through online contact tip-to-workpiece distance adjustment

Elena Manoli1 Rosa Abate1 Yushuai Che2 Luigi Nele1 Guido Guizzi1 Giulio Mattera1*
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1 Department of Chemical, Materials and Production Engineering, University of Naples Federico II, Naples, Italy
2 Department of Management Science and Engineering, Nanjing University of Science and Technology, Nanjing, China
Received: 28 April 2026 | Revised: 26 May 2026 | Accepted: 7 June 2026 | Published online: 8 July 2026
© 2026 by the Author(s). This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution 4.0 International License ( https://creativecommons.org/licenses/by/4.0/ )
Abstract

Wire arc additive manufacturing (WAAM) is attracting increasing interest for the production of large metallic components due to its high material efficiency and productivity. However, process instability and heat input fluctuations can compromise geometric consistency, process reliability, and compliance with qualification requirements, while also affecting energy consumption and environmental performance. This study investigates the environmental implications of feedback-controlled heat-input regulation in WAAM of Invar 36, with particular emphasis on carbon footprint through life cycle assessment (LCA). In contrast to conventional WAAM control strategies, which typically target bead geometry, the proposed approach regulates thermal input through online adjustment of the contact tip-to-workpiece distance (CTWD). This enables heat-input control while preserving the nominal welding parameters, which is particularly relevant for qualification-oriented manufacturing. By combining layer-wise thin-wall experiments with scale-up to an industrial Invar 36 component, the study shows that closed-loop heat-input control increased deposited mass per layer by up to 33.8%, while reducing specific energy consumption and WAAM-only global warming potential (GWP) by up to 25.4% and 25.6%, respectively. At the component scale, the measured energy demand decreased from 8.17 to 7.65 kWh and the WAAM-only GWP from 13.2 to 12.5 kg CO₂-eq. These findings confirm that heat-input regularisation improves WAAM process efficiency and process-related sustainability. However, because feedstock production dominates the total environmental impact, the full carbon-footprint benefit can only be achieved if geometry- or mass-based feedback prevents unnecessary material over-deposition. The results therefore indicate that closed-loop control provides the greatest environmental advantage under equal deposited-mass conditions.

Graphical abstract
Keywords
Wire arc additive manufacturing
Invar 36
Feedback control
Environmental impact assessment
Life cycle assessment
Funding
The research was funded by the INVITALIA Project NEMESI.
Conflict of interest
Giulio Mattera serves the Editorial Board of this journal as a youth member, but was not in any way involved in the editorial and peer-review process conducted for this paper, directly or indirectly. The authors declare they have no competing interests.
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Materials Science in Additive Manufacturing, Electronic ISSN: 2810-9635 Published by AccScience Publishing