Prediction of welding bead geometry for wire arc additive manufacturing of SS308l walls using response surface methodology
Email:
thaomta@gmail.com
Keywords:
Wire arc additive manufacturing, gas metal arc welding, welding bead geometry, response surface methodology, ANOVA.
Abstract
In the wire arc additive manufacturing (WAAM) process, the geometry of single welding beads has significant effects on the stability process and the final quality and shape of manufactured parts. In this paper, the geometry of single welding beads of 308L stainless steel was predicted as functions of process parameters (i.e. welding current I, voltage U, and travel speed v) by using the response surface methodology (RSM). A set of experimental runs was carried out by using the Box-Behnken design method. The adequacy of the developed models was assessed by using an analysis of variance (ANOVA). The results indicate that the RSM allows the predictive models of bead width (BW) and bead height (BH) to be developed with a high accuracy: R2-values of BW and BH are 99.01% and 99.61%, respectively. The errors between the predicted and experimental values for the confirmatory experiments are also lower than 5% that again confirms the adequacy of the developed models. These developed models can efficiently be used to predict the desirable geometry of welding beads for the adaptive slicing principle in WAAM.References
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[2]. V.T. Le, H. Paris, G. Mandil, Environmental impact assessment of an innovative strategy based on an additive and subtractive manufacturing combination, J. Clean. Prod., 164 (2017) 508–523. https://doi.org/10.1016/j.jclepro.2017.06.204
[3]. V.T. Le, H. Paris, A life cycle assessment-based approach for evaluating the influence of total build height and batch size on the environmental performance of electron beam melting, Int. J. Adv. Manuf. Technol., 98 (2018) 275–288. https://doi.org/10.1007/s00170-018-2264-7
[4]. K.S. Derekar, A review of wire arc additive manufacturing and advances in wire arc additive manufacturing of aluminium, Mater. Sci. Technol., 34 (2018) 895–916. https://doi.org/10.1080/02670836.2018.1455012
[5]. D. Ding, Z. Pan, D. Cuiuri, H. Li, Wire-feed additive manufacturing of metal components: technologies, developments and future interests, Int. J. Adv. Manuf. Technol., 81 (2015) 465–481. https://doi.org/10.1007/s00170-015-7077-3
[6]. S.W. Williams, F. Martina, A.C. Addison, J. Ding, G. Pardal, P. Colegrove, Wire + Arc Additive Manufacturing, Mater. Sci. Technol. 32 (2016) 641–647. https://doi.org/10.1179/1743284715Y.0000000073
[7]. J. Xiong, Y. Li, R. Li, Z. Yin, Influences of process parameters on surface roughness of multi-layer single-pass thin-walled parts in GMAW-based additive manufacturing, J. Mater. Process. Technol., 252 (2018) 128–136. https://doi.org/10.1016/j.jmatprotec.2017.09.020
[8]. Z. Zhang, C. Sun, X. Xu, L. Liu, Surface quality and forming characteristics of thin-wall aluminium alloy parts manufactured by laser assisted MIG arc additive manufacturing, Int. J. Light. Mater. Manuf., 1 (2018) 89–95. https://doi.org/10.1016/j.ijlmm.2018.03.005
[9]. S. Jindal, R. Chhibber, N.P. Mehta, Effect of welding parameters on bead profile, microhardness and H 2 content in submerged arc welding of high-strength low-alloy steel, Proc. Inst. Mech. Eng. Part B J. Eng. Manuf. 228 (2014) 82–94. https://doi.org/10.1177/0954405413495846
[10]. G. Magudeeswaran, S.R. Nair, L. Sundar, N. Harikannan, Optimization of process parameters of the activated tungsten inert gas welding for aspect ratio of UNS S32205 duplex stainless steel welds, Def. Technol., 10 (2014) 251–260. https://doi.org/10.1016/j.dt.2014.06.006
[11]. S. Srivastava, R.K. Garg, Process parameter optimization of gas metal arc welding on IS:2062 mild steel using response surface methodology, J. Manuf. Process., 25 (2017) 296–305. https://doi.org/10.1016/j.jmapro.2016.12.016
[12]. J. Xiong, G. Zhang, W. Zhang, Forming appearance analysis in multi-layer single-pass GMAW-based additive manufacturing, Int. J. Adv. Manuf. Technol., 80 (2015) 1767–1776. https://doi.org/10.1007/s00170-015-7112-4
[13]. X. Lu, Y.F. Zhou, X.L. Xing, L.Y. Shao, Q.X. Yang, S.Y. Gao, Open-source wire and arc additive manufacturing system: formability, microstructures, and mechanical properties, Int. J. Adv. Manuf. Technol., 93 (2017) 2145–2154. https://doi.org/10.1007/s00170-017-0636-z
[14]. H. Takagi, H. Sasahara, T. Abe, H. Sannomiya, S. Nishiyama, S. Ohta, K. Nakamura, Material-property evaluation of magnesium alloys fabricated using wire-and-arc-based additive manufacturing, Addit. Manuf., 24 (2018) 498–507. https://doi.org/10.1016/j.addma.2018.10.026
[15]. M. Dinovitzer, X. Chen, J. Laliberte, X. Huang, H. Frei, Effect of wire and arc additive manufacturing (WAAM) process parameters on bead geometry and microstructure, Addit. Manuf., 26 (2019) 138–146. https://doi.org/10.1016/j.addma.2018.12.013
[16]. M. Rafieazad, M. Ghaffari, A. Vahedi Nemani, A. Nasiri, Microstructural evolution and mechanical properties of a low-carbon low-alloy steel produced by wire arc additive manufacturing, Int. J. Adv. Manuf. Technol., 105 (2019) 2121–2134. https://doi.org/10.1007/s00170-019-04393-8
[17]. V.T. Le, A preliminary study on gas metal arc welding-based additive manufacturing of metal parts, Sci. Technol. Dev. J. 23 (2020) 422–429. https://doi.org/10.32508/stdj.v23i1.1714
[18]. X. Chen, J. Li, X. Cheng, B. He, H. Wang, Z. Huang, Microstructure and mechanical properties of the austenitic stainless steel 316L fabricated by gas metal arc additive manufacturing, Mater. Sci. Eng. A., 703 (2017) 567–577. https://doi.org/10.1016/j.msea.2017.05.024
[19]. C. V. Haden, G. Zeng, F.M. Carter, C. Ruhl, B.A. Krick, D.G. Harlow, Wire and arc additive manufactured steel: Tensile and wear properties, Addit. Manuf., 16 (2017) 115–123. https://doi.org/10.1016/j.addma.2017.05.010
[20]. W. Wu, J. Xue, Z. Zhang, P. Yao, Comparative study of 316L depositions by two welding current processes, Mater. Manuf. Process., 34 (2019) 1502-1508. https://doi.org/10.1080/10426914.2019.1643473
[21]. V. Gunaraj, N. Murugan, Application of response surface methodology for predicting weld bead quality in submerged arc welding of pipes, J. Mater. Process. Technol., 88 (1999) 266–275. https://doi.org/10.1016/S0924-0136(98)00405-1
[22]. S. Jindal, R. Chhibber, N.P. Mehta, Effect of welding parameters on bead profile, microhardness and H 2 content in submerged arc welding of high-strength low-alloy steel, Proc. Inst. Mech. Eng. Part B J. Eng. Manuf. 228 (2014) 82–94. https://doi.org/10.1177/0954405413495846
[23]. I. Jurić, I. Garašić, M. Bušić, Z. Kožuh, Influence of Shielding Gas Composition on Structure and Mechanical Properties of Wire and Arc Additive Manufactured Inconel 625, Jom., 71 (2019) 703–708. https://doi.org/10.1007/s11837-018-3151-2
[24]. F. Youheng, W. Guilan, Z. Haiou, L. Liye, Optimization of surface appearance for wire and arc additive manufacturing of Bainite steel, Int. J. Adv. Manuf. Technol., 91 (2017) 301–313. https://doi.org/10.1007/s00170-016-9621-1
[25]. D. Yang, G. Wang, G. Zhang, Thermal analysis for single-pass multi-layer GMAW based additive manufacturing using infrared thermography, J. Mater. Process. Technol., 244 (2017) 215–224. https://doi.org/10.1016/j.jmatprotec.2017.01.024
[26]. J. Xiong, Z. Yin, W. Zhang, Forming appearance control of arc striking and extinguishing area in multi-layer single-pass GMAW-based additive manufacturing, Int. J. Adv. Manuf. Technol., 87 (2016) 579–586. https://doi.org/10.1007/s00170-016-8543-2
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Received
21/04/2020
Revised
19/05/2020
Accepted
20/05/2020
Published
28/05/2020
Type
Research Article
How to Cite
Van Thao, L., Dinh Si, M., Tat Khoa, D., & Quang Huy, H. (1590598800). Prediction of welding bead geometry for wire arc additive manufacturing of SS308l walls using response surface methodology. Transport and Communications Science Journal, 71(4), 431-443. https://doi.org/10.25073/tcsj.71.4.11
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