| This study investigates the influence of two scanning strategies (90° and 45°) on the angular distortion and hardness distribution in wire arc additive manufacturing (WAAM) as applied to remanufacturing applications. Using austenitic stainless steel 1.4301 as the substrate and 1.4370 as the deposited material, single-layer deposition was conducted using a custom-built GMAW-based WAAM system. The 90° strategy resulted in greater angular distortion, indicating a higher temperature gradient and residual stress compared to the 45° strategy. Microstructural morphology analysis revealed equiaxed dendritic formations in the fusion zone, cellular and columnar structures in the transition zone, and coarse grains in the heat affected zone. Vickers hardness testing (HV 0.5) showed deposited layer and heat affected zone had lower hardness values than the reference substrate layer with the 90° strategy produced a wider hardness distribution range. These findings emphasize that scanning strategies control the heat profile, to which geometrical and mechanical properties are affected. |