Abstract
<title>Abstract</title> <p>Interlayer dwell time in wire arc additive manufacturing (WAAM) is often treated as a single process threshold, but sparse datasets can support different limits depending on the indicator and analysis. We reanalysed twelve single-pass multilayer walls—six ER70S-6 and six ER110S-G—with one wall at each of six nominal dwell conditions from 0 to 240 s. Geometry, radiographic classification and hardness were traced to their released records. We evaluated geometric recovery under alternative criteria, saturation laws, leave-one-out deletion and 0.1 mm height quantisation. The first tested dwell satisfying the illustrative criteria ranged from 30 to 240 s, with one fitted crossing beyond the tested range; the rounding analysis did not change this overall range. Both alloys completed about three-quarters of their observed geometric change by 30 s. ER70S-6 cap-region means showed no clear plateau, but the 120–240 s difference is cumulative over a 120 s interval and includes one endpoint wall. Radiographic classification showed no monotonic ordering with dwell. The data therefore support a sensitivity-based screening workflow, not a unique process boundary: geometry, radiography and hardness should remain separate evidence streams until repeated builds and qualified acceptance criteria are available.</p>