The macro-structure, microstructure and mechanical properties of 4043 aluminium-alloy parts manufactured by variable polarity cold metal transfer welding (CMT + Advance) have been investigated. The results showed that processing parameters have a strong effect on the geometry, microstructures, roughness and hardness of a deposited part. The problem of the hump and arc collapse was solved by the adjustment of specific welding parameters. Different morphologies were formed at different locations according to the observation of the microstructure. The elemental segregation was found between the layers of the component. The results showed that the dimensional accuracy of the single wall forming sample could be controlled much better by means of adjusting the parameters and optimising the path, thus excellent sample would be obtained.

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