DEVELOPMENT OF MULTI-MATERIAL COMPONENTS VIA ROBOTIC WIRE ARC ADDITIVE MANUFACTURING
Year 2021,
, 721 - 729, 30.12.2021
Uğur Gürol
,
Batuhan Turgut
,
Nurten Güleçyüz
,
Savaş Dilibal
,
Mustafa Koçak
Abstract
Additive manufacturing technologies are applied in different industrial fields. It is possible to produce 3D parts in complex form at a lower cost with faster production capability using additive manufacturing compared to traditional subtractive manufacturing. Robotic welding-based wire arc additive manufacturing (WAAM) is a novel additive manufacturing technology which offers various solutions. Many products can be produced through the additive manufacturing in the fields of defense, aerospace, and automotive industries. In this study, multi-material metallic parts were produced by depositing ferritic ER 70 S-6 and stainless steel ER316L welding wires using robotic WAAM technology. Detailed microstructural analysis and hardness tests were conducted on the manufactured samples including interfaces between two different materials. Characterization of Fe-austenite weld interfaces has shown the presence of hard phases due to migration of hardening elements. The microhardness examination revealed that the highest hardness values are recorded at the bimetallic interface due to Fe and C migration through the interface layer.
Thanks
This study was carried out with the coordination of Gedik Welding R&D Center, Istanbul Gedik University Welding Technology Application and Research Center and Robotic Technologies Application and Research Center.
References
- Frazier, W.E., “Metal additive manufacturing: A review”, Journal of Material Engineering and Performance, Vol. 23, Pages 1917–1928, 2014.
- Williams, S.W., Martina, F., Addison, A. C., Ding, J., Pardal, G., Colegrove, P., “Wire+Arc additive manufacturing”, Materials Science and Technology, Vol. 32, Issue 7, Pages 641-647, 2016.
- Leal, R., Barreiros, F.M., Alves, L., Romeiro, F., Vasco, J.C., Santos, M., Marto, C., “Additive manufacturing tooling for the automotive industry”, The International Journal of Advanced Manufacturing Technology, Vol. 92, Pages 1671–1676, 2017.
- Pan, Z., Ding, D., Wu, B., Cuiuri, D., Li, H., Norrish, J., “Arc welding processes for additive manufacturing: A review”, Transactions on Intelligent Welding Manufacturing, Vol. 1, Pages 3-24 2018.
- Mehnen, J., Ding, J., Lockett, H., Kazanas, P., “Design study for wire and arc additive manufacture”, International Journal of Product Development, Vol. 19, Issue 2, Pages 2-20, 2014.
- Jin, W., Zhang, C., Jin, S., Tian, Y., Wellmann, D., Liu, W., “Wire arc additive manufacturing of stainless steels: A review”, Applied Sciences, Vol. 10, Issue 5:1563, 2020.
- Chen, Z., Yufei, L., Ming, G., Xiaoyan, Z., “Wire arc additive manufacturing of Al-6Mg alloy using variable polarity cold metal transfer arc as power source”, Materials Science & Engineering A, Vol. 711, Pages 415-423, 2018.
- Shen, C., Pan, Z., Ma, Y. et al., “Fabrication of iron-rich Fe–Al intermetallics using the wire-arc additive manufacturing process”, Additive Manufacturing, Vol. 7, Pages 20–26, 2015.
- Colegrove, P., Coules, H., Fairman, J., Martina, F., Kashoob, T., Mamash, H., Cozzolino, L.D., “Microstructure and residual stress improvement in wire and arc additively manufactured parts through high-pressure rolling”, Journal of Materials Processing Technology, Vol. 213, Pages 1782–1791, 2013.
- Li Xiong, J., Li, Y. R., Yin, Z., “Influences of process parameters on surface roughness of multi-layer single-pass thin-walled parts in GMAW-based additive manufacturing” Journal of Materials Processing Technology, Vol. 252, Pages 128–136, 2018.
- Wilson, I.L.W. Gourley, R.G., Walkosak, R.M., Bruck, G.J., “The effect of heat input on microstructure and cracking in alloy 625 weld overlays”, Proceedings of the International Symposium on the Metallurgy and Applications of Superalloys 718, 625 and Various Derivatives, Pages 735–747, Pittsburgh, 1991.
- Chaurasia, M., Sinha, M.K., “Investigations on process parameters of wire arc additive manufacturing (WAAM): A review”, Advances in Manufacturing and Industrial Engineering, Pages 845-85, 2021.
- Ahsan, M.R.U., Tanvir, A.N.M., Ross, T., Elsawy, A., Oh, M.-S. and Kim, D.B., "Fabrication of bimetallic additively manufactured structure (BAMS) of low carbon steel and 316L austenitic stainless steel with wire + arc additive manufacturing", Rapid Prototyping Journal, Vol. 26, Pages 519-530, 2020.
- Kumar, S.M., Kannan, A.R., Kumar, N.P., Pramod, R., Shanmugam, N.S., Vishnu, A.S., Channabasavanna, S.G., “Microstructural features and mechanical integrity of wire arc additive manufactured SS321/Inconel 625 functionally gradient material”, Journal of Materials Engineering and Performance, Vol. 30, Issue 8, Pages 5692-5703, 2021.
- Xu, X., “Wire arc additive manufacturing of new and multiple materials”, Ph.D. Thesis, Cranfield University, Cranfield, 2019.
- Haselhuhn, A.S., Wijnen, B., Anzalone, G.C., Sanders P.G., Pearce J.M., “In situ formation of substrate release mechanisms for gas metal arc weld metal 3-D printing”, Journal of Materials Processing Technology, Vol. 226, Pages 50-59, 2015.
- Yılmaz, R., Tümer, M., “Microstructural studies and impact toughness of dissimilar weldments between AISI 316 L and AH36 steels by FCAW”, The International Journal of Advanced Manufacturing Technology, Vol. 67, Pages 1433–1447, 2013.
- Kapustka, N., Conrardy, C., Babu, S., Albright, C., “Effect of GMAW process and material conditions on DP 780 and TRIP 780 welds”, Welding Journal, Vol. 87, Issue 6, Pages 135-148, 2008.
DEVELOPMENT OF MULTI-MATERIAL COMPONENTS VIA ROBOTIC WIRE ARC ADDITIVE MANUFACTURING
Year 2021,
, 721 - 729, 30.12.2021
Uğur Gürol
,
Batuhan Turgut
,
Nurten Güleçyüz
,
Savaş Dilibal
,
Mustafa Koçak
Abstract
Additive manufacturing technologies are applied in different industrial fields. It is possible to produce 3D parts in complex form at a lower cost with faster production capability using additive manufacturing compared to traditional subtractive manufacturing. Robotic welding-based wire arc additive manufacturing (WAAM) is a novel additive manufacturing technology which offers various solutions. Many products can be produced through the additive manufacturing in the fields of defense, aerospace, and automotive industries. In this study, multi-material metallic parts were produced by depositing ferritic ER 70 S-6 and stainless steel ER316L welding wires using robotic WAAM technology. Detailed microstructural analysis and hardness tests were conducted on the manufactured samples including interfaces between two different materials. Characterization of Fe-austenite weld interfaces has shown the presence of hard phases due to migration of hardening elements. The microhardness examination revealed that the highest hardness values are recorded at the bimetallic interface due to Fe and C migration through the interface layer.
References
- Frazier, W.E., “Metal additive manufacturing: A review”, Journal of Material Engineering and Performance, Vol. 23, Pages 1917–1928, 2014.
- Williams, S.W., Martina, F., Addison, A. C., Ding, J., Pardal, G., Colegrove, P., “Wire+Arc additive manufacturing”, Materials Science and Technology, Vol. 32, Issue 7, Pages 641-647, 2016.
- Leal, R., Barreiros, F.M., Alves, L., Romeiro, F., Vasco, J.C., Santos, M., Marto, C., “Additive manufacturing tooling for the automotive industry”, The International Journal of Advanced Manufacturing Technology, Vol. 92, Pages 1671–1676, 2017.
- Pan, Z., Ding, D., Wu, B., Cuiuri, D., Li, H., Norrish, J., “Arc welding processes for additive manufacturing: A review”, Transactions on Intelligent Welding Manufacturing, Vol. 1, Pages 3-24 2018.
- Mehnen, J., Ding, J., Lockett, H., Kazanas, P., “Design study for wire and arc additive manufacture”, International Journal of Product Development, Vol. 19, Issue 2, Pages 2-20, 2014.
- Jin, W., Zhang, C., Jin, S., Tian, Y., Wellmann, D., Liu, W., “Wire arc additive manufacturing of stainless steels: A review”, Applied Sciences, Vol. 10, Issue 5:1563, 2020.
- Chen, Z., Yufei, L., Ming, G., Xiaoyan, Z., “Wire arc additive manufacturing of Al-6Mg alloy using variable polarity cold metal transfer arc as power source”, Materials Science & Engineering A, Vol. 711, Pages 415-423, 2018.
- Shen, C., Pan, Z., Ma, Y. et al., “Fabrication of iron-rich Fe–Al intermetallics using the wire-arc additive manufacturing process”, Additive Manufacturing, Vol. 7, Pages 20–26, 2015.
- Colegrove, P., Coules, H., Fairman, J., Martina, F., Kashoob, T., Mamash, H., Cozzolino, L.D., “Microstructure and residual stress improvement in wire and arc additively manufactured parts through high-pressure rolling”, Journal of Materials Processing Technology, Vol. 213, Pages 1782–1791, 2013.
- Li Xiong, J., Li, Y. R., Yin, Z., “Influences of process parameters on surface roughness of multi-layer single-pass thin-walled parts in GMAW-based additive manufacturing” Journal of Materials Processing Technology, Vol. 252, Pages 128–136, 2018.
- Wilson, I.L.W. Gourley, R.G., Walkosak, R.M., Bruck, G.J., “The effect of heat input on microstructure and cracking in alloy 625 weld overlays”, Proceedings of the International Symposium on the Metallurgy and Applications of Superalloys 718, 625 and Various Derivatives, Pages 735–747, Pittsburgh, 1991.
- Chaurasia, M., Sinha, M.K., “Investigations on process parameters of wire arc additive manufacturing (WAAM): A review”, Advances in Manufacturing and Industrial Engineering, Pages 845-85, 2021.
- Ahsan, M.R.U., Tanvir, A.N.M., Ross, T., Elsawy, A., Oh, M.-S. and Kim, D.B., "Fabrication of bimetallic additively manufactured structure (BAMS) of low carbon steel and 316L austenitic stainless steel with wire + arc additive manufacturing", Rapid Prototyping Journal, Vol. 26, Pages 519-530, 2020.
- Kumar, S.M., Kannan, A.R., Kumar, N.P., Pramod, R., Shanmugam, N.S., Vishnu, A.S., Channabasavanna, S.G., “Microstructural features and mechanical integrity of wire arc additive manufactured SS321/Inconel 625 functionally gradient material”, Journal of Materials Engineering and Performance, Vol. 30, Issue 8, Pages 5692-5703, 2021.
- Xu, X., “Wire arc additive manufacturing of new and multiple materials”, Ph.D. Thesis, Cranfield University, Cranfield, 2019.
- Haselhuhn, A.S., Wijnen, B., Anzalone, G.C., Sanders P.G., Pearce J.M., “In situ formation of substrate release mechanisms for gas metal arc weld metal 3-D printing”, Journal of Materials Processing Technology, Vol. 226, Pages 50-59, 2015.
- Yılmaz, R., Tümer, M., “Microstructural studies and impact toughness of dissimilar weldments between AISI 316 L and AH36 steels by FCAW”, The International Journal of Advanced Manufacturing Technology, Vol. 67, Pages 1433–1447, 2013.
- Kapustka, N., Conrardy, C., Babu, S., Albright, C., “Effect of GMAW process and material conditions on DP 780 and TRIP 780 welds”, Welding Journal, Vol. 87, Issue 6, Pages 135-148, 2008.