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Wire Arc Additive Manufacturing (WAAM) is a promising method to build large metal structures through multi-pass multi-layer deposition. However, during WAAM processing of complex structures using traditional contour paths, filling gaps are easily left at sharp corners due to excessive self-overlapping and under-filling. This study focuses on the development of a corner path optimization strategy in order to improve the capability of the WAAM process in producing gap-free metal components. Firstly, based on the traditional contour paths, an innovative corner path optimization method was developed to generate multi-pass paths with varying centre distances and extra gap-fill paths at corners which avoid excessive self-overlapping and under-filling. Then an Artificial Neural Networks (ANNs) bead model was established to select the welding parameters which are adaptive to the modified multi-pass paths at corners. The capability of WAAM to deposit the welding bead with varying widths but a c ....

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