**3. Results**

#### *3.1. Comparison of the Build-Up Height and the Resulting Diameters*

The resulting bar diameters, including minimum and maximum values, as well as the mean build-up heights of the single layers were examined and are displayed in Figure 6. Furthermore, the

energy input per layer was calculated by Equation (1), since there is no welding velocity for calculating the regular energy per unit length:

$$E = lI \times I \times t\_{\text{world}} \tag{1}$$

For measurement of the welding time per layer (*tweld*), the current (*I*), and the voltage (*U*), a measurement device (HKS weld monitoring system) was connected to the power source. The according energy per layer is also shown in Figure 6.

**Figure 6.** Layer build-up height, diameter, layer volume, and the corresponding energy input of different welding processes.

The conventional GMAW obtained the highest build-up rate with more than a 3.3 mm layer height as well as the thickest bar diameter with almost 10 mm. The CMT cycle step reached 1.4 mm as the lowest layer height and a bar diameter of 9.16 mm. The CMT standard process achieved layer heights of 2.15 mm and diameters of 8.2 mm. Since the build-up height correlates with the energy per layer while the diameter does not, the layer volume was also calculated and is depicted in Figure 6. The layer volume increased with higher energy input per layer.
