Comparative Process Parameter Optimization For Wire Arc Additive Manufacturing (WAAM) of E120C-GH4 Metal Cored and ER120S-G Solid Wire

Mustafa Harman; Cemil Çetinkaya; Oğuzhan Yılmaz; Nevzat Bol

Makale detayları

Comparative Process Parameter Optimization For Wire Arc Additive Manufacturing (WAAM) of E120C-GH4 Metal Cored and ER120S-G Solid Wire

Yazarlar:

Mustafa Harman | Cemil Çetinkaya | Oğuzhan Yılmaz | Nevzat Bol

Yayıncı:

Gazi University

Ana Başlıklar:

Kaynak Teknolojileri

Dergi:

Politeknik Dergisi Vol.27 Issue 5, pp.2013-2028

Belge Tipi:

Makale

Yayın Tarihi:

2/2024

Belge Dili:

İngilizce

Document ID (Org No.):

2001331590

pISSN:

2147-9429

Anahtar kelimeler:

Özet:

 Wire arc additive manufacturing WAAM method is a metal additive manufacturing method that allows the production of large and medium complexity parts layer by layer by considering the part-specific CAD model. Process parameters were optimized to achieve minimum heat input, less production time, and higher metal deposition rate and bead geometry. E120C-GH4 metal-cored seamless high-strength wire with a diameter of 1.2 mm and an ER120S-G solid wire of the same diameter were used at different wire feeding speeds with heat input low, medium, high. Single and double layer 18 beads were deposited with each of these wires. Samples were prepared for macro section examination and macro hardness measurement processes. Samples with similar deposition volumes were compared in terms of bead geometry, microhardness, penetration depth, deposition time, and the metal deposition rate at the equal heat input. With the aid of the Taguchi method and the samples were subjected to multiple regression analyses. So, the analyses and real experiments allowed comparative experimental studies. Considering the economy and time, the result shows that metal-cored wire will be much preferable for the WAAM industry because metal-cored wire has 43 less production time and 74 higher metal deposition rate than solid wire.

 Wire arc additive manufacturing WAAM method is a metal additive manufacturing method that allows the production of large and medium complexity parts layer by layer by considering the part-specific CAD model. Process parameters were optimized to achieve minimum heat input, less production time, and higher metal deposition rate and bead geometry. E120C-GH4 metal-cored seamless high-strength wire with a diameter of 1.2 mm and an ER120S-G solid wire of the same diameter were used at different wire feeding speeds with heat input low, medium, high. Single and double layer 18 beads were deposited with each of these wires. Samples were prepared for macro section examination and macro hardness measurement processes. Samples with similar deposition volumes were compared in terms of bead geometry, microhardness, penetration depth, deposition time, and the metal deposition rate at the equal heat input. With the aid of the Taguchi method and the samples were subjected to multiple regression analyses. So, the analyses and real experiments allowed comparative experimental studies. Considering the economy and time, the result shows that metal-cored wire will be much preferable for the WAAM industry because metal-cored wire has 43 less production time and 74 higher metal deposition rate than solid wire.

 Wire arc additive manufacturing WAAM method is a metal additive manufacturing method that allows the production of large and medium complexity parts layer by layer by considering the part-specific CAD model. Process parameters were optimized to achieve minimum heat input, less production time, and higher metal deposition rate and bead geometry. E120C-GH4 metal-cored seamless high-strength wire with a diameter of 1.2 mm and an ER120S-G solid wire of the same diameter were used at different wire feeding speeds with heat input low, medium, high. Single and double layer 18 beads were deposited with each of these wires. Samples were prepared for macro section examination and macro hardness measurement processes. Samples with similar deposition volumes were compared in terms of bead geometry, microhardness, penetration depth, deposition time, and the metal deposition rate at the equal heat input. With the aid of the Taguchi method and the samples were subjected to multiple regression analyses. So, the analyses and real experiments allowed comparative experimental studies. Considering the economy and time, the result shows that metal-cored wire will be much preferable for the WAAM industry because metal-cored wire has 43 less production time and 74 higher metal deposition rate than solid wire.

 Tel ark eklemeli imalat WAAM yöntemi, parçaya özel CAD modeli dikkate alınarak büyük ve orta karmaşıklıktaki parçaların katman katman üretilmesine olanak sağlayan bir metal eklemeli imalat yöntemidir. Proses parametreleri, minimum ısı girdisi, daha az üretim süresi, daha yüksek metal biriktirme hızı ve duvar geometrisi elde etmek üzere optimize edildi. 1,2 mm çapında E120C-GH4 metal özlü dikişsiz yüksek mukavemetli tel ve aynı çapta ER120S-G masif tel, düşük, orta, yüksek ısı girdili farklı tel besleme hızlarında kullanıldı. Bu tellerin her birine tek ve çift katmanlı 18 tane duvar biriktirildi. Makro kesit incelemesi ve makro sertlik ölçümü işlemleri için numuneler hazırlandı. Benzer biriktirme hacimlerine sahip numuneler duvar geometrisi, mikrosertlik, penetrasyon derinliği, biriktirme süresi ve eşit ısı girdisinde metal biriktirme hızı açısından karşılaştırıldı. Taguchi yöntemi yardımıyla örnekler çoklu regresyon analizine tabi tutuldu. Böylece analizler ve gerçek deneyler karşılaştırmalı deneysel çalışmalara olanak sağladı. Sonuç, ekonomi ve zaman dikkate alındığında, metal özlü telin WAAM endüstrisi için daha çok tercih edileceğini göstermektedir çünkü metal özlü tel, masif telden 43 daha az üretim süresine ve 74 daha yüksek metal biriktirme oranına sahiptir.

Makale detayları

Comparative Process Parameter Optimization For Wire Arc Additive Manufacturing (WAAM) of E120C-GH4 Metal Cored and ER120S-G Solid Wire

Yazarlar:

Mustafa Harman | Cemil Çetinkaya | Oğuzhan Yılmaz | Nevzat Bol

Yayıncı:

Gazi University

Ana Başlıklar:

Kaynak Teknolojileri

Dergi:

Politeknik Dergisi Vol.27 Issue 5, pp.2013-2028

Belge Tipi:

Makale

Yayın Tarihi:

2/2024

Belge Dili:

İngilizce

Document ID (Org No.):

2001331590

pISSN:

2147-9429

Metal cored wire

Taguchi method

Armor steel

WAAM

macro section.Metal özlü tel

Taguchi metodu

zırh çeliği

WAAM

Makro kesit

Sayı

Makale detayları

Yazarlar: Mustafa Harman | Cemil Çetinkaya | Oğuzhan Yılmaz | Nevzat Bol

Yayıncı: Gazi University

Ana Başlıklar: Kaynak Teknolojileri

Dergi: Politeknik Dergisi Vol.27 Issue 5, pp.2013-2028

Belge Tipi: Makale

Yayın Tarihi: 2/2024

Belge Dili: İngilizce

Document ID (Org No.): 2001331590

pISSN: 2147-9429

Sayı

Yazarlar:

Mustafa Harman | Cemil Çetinkaya | Oğuzhan Yılmaz | Nevzat Bol

Yayıncı:

Gazi University

Ana Başlıklar:

Kaynak Teknolojileri

Dergi:

Politeknik Dergisi Vol.27 Issue 5, pp.2013-2028

Belge Tipi:

Makale

Yayın Tarihi:

2/2024

Belge Dili:

İngilizce

Document ID (Org No.):

2001331590

pISSN:

2147-9429