INVESTIGATION OF THE EFFECT OF WELDING WIRE ON THE TRIBOLOGICAL PROPERTIES OF AISI 1050 STEEL REPAIRED BY MIG AND ARC WELDING

Year 2024, , 1279 - 1289, 12.08.2024

Koray Kılıçay , Mustafa Çağatay Ergene , Salih Can Dayı

https://doi.org/10.31796/ogummf.1404233

Abstract

In recent years, repairing and reusing damaged machine parts with low-cost welding methods has become common. In this study, repair processes were applied to AISI 1050 steel using MIG and arc welding methods, widely used in the manufacturing industry, and five different welding wires. SG2 quality and stainless welding wires were used in the MIG method, and rutile, basic and stainless welding wires were used in arc welding. The repaired samples' microstructure, microhardness, friction, and wear behaviors were examined. Microstructural examinations were carried out using optical microscopy. Wear tests were performed using the pin-disc method under dry conditions in accordance with the ASTM G99 standard. Specific wear rates were calculated by measuring wear channels with a surface profilometer. The worn surfaces were examined by SEM and EDS analysis and the wear mechanisms were determined. No microstructural defects such as cracks, voids, etc. were detected in the weld areas of the repaired samples. The microhardness values of all repaired samples were higher than AISI 1050 steel. The highest average microhardness values were detected in samples repaired with stainless welding wire. After the repair operations, the wear performance of the samples increased approximately 3 times. The highest wear resistance was determined in the sample using the MIG method and SG2 quality welding wire.

Keywords

MIG, Welding wire, Repair, Friction and wear

MIG VE ARK KAYNAĞI İLE TAMİR EDİLMİŞ AISI 1050 ÇELİĞİNİN TRİBOLOJİK ÖZELLİKLERİNE KAYNAK TELİNİN ETKİSİNİN İNCELENMESİ

Abstract

Son yıllarda hasar görmüş makine parçalarının düşük maliyetli kaynak yöntemleri ile tamir edilip tekrar kullanılması yaygın hale gelmiştir. Bu çalışmada imalat sektöründe yaygın olarak kullanılan MIG ve ark kaynak yöntemleri ile beş farklı kaynak teli kullanılarak AISI 1050 çeliğine kaynaklı tamir işlemleri uygulanmıştır. MIG yönteminde SG2 kalite ve paslanmaz kaynak telleri, ark kaynağında rutil, bazik ve paslanmaz kaynak telleri kullanılmıştır. Tamir edilmiş numunelerin mikroyapı, mikrosertlik, sürtünme ve aşınma davranışları incelenmiştir. Mikroyapı incelemeleri optik mikroskop ile gerçekleştirilmiştir. Aşınma deneyleri ASTM G99 standartına uygun olarak kuru şartlarda pim-disk yöntemi ile yapılmıştır. Aşınma kanalları yüzey profilometresi ile ölçülerek spesfik aşınma oranları hesaplanmıştır. Aşınmış yüzeyler SEM ve EDS analizi ile incelenerek aşınma mekanizmaları belirlenmiştir. Tamir edilmiş numunelerin kaynak bölgelerinde çatlak, boşluk vb. mikroyapısal kusurlar tespit edilmemiştir. Tamir edilmiş tüm numunelerin mikrosertlik değerleri AISI 1050 çeliğinden yüksek çıkmıştır. En yüksek ortalama mikrosertlik değerleri paslanmaz kaynak teli ile tamir edilmiş numunelerde tespit edilmiştir. Tamir işlemleri sonrası numunelerin aşınma performansı yaklaşık 3 kat artmıştır. En yüksek aşınma direnci MIG yöntemi ve SG2 kalite kaynak teli kullanılan numunede tespit edilmiştir

Keywords

MIG, Kaynak teli, Tamir, Sürtünme ve aşınma

References

• Ali Rizvi, S., ve Ali, W. (2023). Application of grey-based fuzzy logic algorithm in MIG welding-A case study. Engineering Science and Technology, an International Journal, 42, 101431. doi: 10.1016/j.jestch.2023.101431
• Arslan, M., ve Toplan, N. (2023). AA6061 Serisi Alüminyum Plakalarına Yapılan MIG ve TIG Kaynak Tamirlerinin Tahribatlı ve Tahribatsız Testlerle İncelenmesi. Journal of Materials and Mechatronics: A, 4(1), 333-354. doi: 10.55546/jmm.1284581
• Arunakumara, P. C., Sagar, H. N., Gautam, B., George, R., ve Rajeesh, S. (2023). A review study on fatigue behavior of aluminum 6061 T-6 and 6082 T-6 alloys welded by MIG and FS welding methods. Materials Today: Proceedings, 74, 293-301. doi: 10.1016/j.matpr.2022.08.242
• Ayan, Y., Sarı, E., ve Kahraman, N. (2018). 3B Metal Yazıcı Kullanılarak MIG-MAG Kaynak Yöntemi İle TamirOnarım Kaynak Uygulamasına Bir Örnek Düzce Üniversitesi Bilim ve Teknoloji Dergisi, 6, 1190-1199.
• Başyiğit, A. B. (2020). Alüminyum Esaslı Taşıt Jantlarının TIG Kaynak Yöntemi ile Tamiri Sonrası Kaynak Bölgesinin Mekanik ve Mikroyapısal Özelliklerinin İncelenmesi Uluslararası Mühendislik Araştırma ve Geliştirme Dergisi, 12(2), 388-396.
• Cui, X., Chen, J., Xia, C., Han, X., Su, H., ve Wu, C. (2023). The mechanism study of TIG-MIG hybrid welding process based on simulation. Vacuum, 215, 112341. doi: 10.1016/j.vacuum.2023.112341
• Das Banik, S., Kumar, S., Singh, P. K., ve Bhattacharya, S. (2022). Influence of weld repair on the residual stresses induced in austenitic stainless steel weld joints. Production Engineering, 17(1), 81-94. doi: 10.1007/s11740-022-01156-5
• Dement'yev, V. B., Sterkhov, M. Y., ve Solov'yev, S. D. (2020). Model of the hydrodynamic process of melting and crystallization of metal in the system ‘electric arc – weld pool’. Journal of Crystal Growth, 531, 125335. doi: 10.1016/j.jcrysgro.2019.125335
• Farahani, E. B., Sarhadi, A., Alizadeh-Sh, M., Fæster, S., Danielsen, H. K., ve Eder, M. A. (2023). Thermomechanical modeling and experimental study of a multi-layer cast iron repair welding for weld-induced crack prediction. Journal of Manufacturing Processes, 104, 443-459. doi: 10.1016/j.jmapro.2023.08.059
• Farfan-Cabrera, L. I., Reséndiz-Calderón, C. D., Hernandez-Peña, A., Campos-Silva, I., Gallardo-Hernández, E. A., ve Contla-Pacheco, A. D. (2023). Tribological effects of boriding treatment on a low carbon steel repaired by wire and arc additive manufacturing. Surface and Coatings Technology, 465, 129574. doi: 10.1016/j.surfcoat.2023.129574
• Gagg, C. R., ve Lewis, P. R. (2007). Wear as a product failure mechanism – Overview and case studies. Engineering Failure Analysis, 14(8), 1618-1640. doi: 10.1016/j.engfailanal.2006.11.064
• Gupta, H. N., Gupta, R. C., ve Mittal, A. (2009). Manufacturing Processes (Second Edition ed.): New Age International Publishers.
• Hou, G., Xu, Y., Wang, S., Zhang, Y., She, J., Li, C., . . . Pan, F. (2022). Effects of welding wire composition on the repair welds of sand-cast Mg–Gd–Y alloy: Microstructure and mechanical properties. Vacuum, 199, 110919. doi: 10.1016/j.vacuum.2022.110919
• Lee, J.-H., Lee, C.-M., ve Kim, D.-H. (2022). Repair of damaged parts using wire arc additive manufacturing in machine tools. Journal of Materials Research and Technology, 16, 13-24. doi: 10.1016/j.jmrt.2021.11.156
• Li, S., Dong, H., Wang, X., Liu, Z., Tan, Z., Shangguan, L., . . . Zhong, S. (2020). Effect of repair welding on microstructure and mechanical properties of 7N01 aluminum alloy MIG welded joint. Journal of Manufacturing Processes, 54, 80-88. doi: 10.1016/j.jmapro.2020.03.009
• Li, Y., Han, Q., Horváth, I., ve Zhang, G. (2019). Repairing surface defects of metal parts by groove machining and wire + arc based filling. Journal of Materials Processing Technology, 274, 116268. doi: 10.1016/j.jmatprotec.2019.116268
• Li, Z., Chai, L., Tang, Y., Zhang, C., Qi, L., Zhang, K., . . . Huang, C. (2023). 316L stainless steel repaired layers by weld surfacing and laser cladding on a 27SiMn steel: A comparative study of microstructures, corrosion, hardness and wear performances. Journal of Materials Research and Technology, 23, 2043-2053. doi: 10.1016/j.jmrt.2023.01.162
• Naing, T. H., ve Muangjunburee, P. (2022). Metallurgical and Mechanical Characterization of MIG Welded Repair Joints for 6082-T6 Aluminum Alloy with ER 4043 and ER 5356. Transactions of the Indian Institute of Metals, 75(6), 1583-1593. doi: 10.1007/s12666-022-02523-7
• Sahoo, A., ve Tripathy, S. (2021). Development in plasma arc welding process: A review. Materials Today: Proceedings, 41, 363-368. doi: 10.1016/j.matpr.2020.09.562
• Singh, S., Kumar, V., Kumar, S., ve Kumar, A. (2022). Variant of MIG welding of similar and dissimilar metals: A review. Materials Today: Proceedings, 56, 3550-3555. doi: 10.1016/j.matpr.2021.11.287
• Tesfaye, F. K., ve Getaneh, A. M. (2023). The Grey-Based Taguchi Method was used to enhance the TIG-MIG hybrid welding process parameters for mild steel. Invention Disclosure, 100016. doi: 10.1016/j.inv.2023.100016
• Yurioka, N., ve Horii, Y. (2013). Recent developments in repair welding technologies in Japan. Science and Technology of Welding and Joining, 11(3), 255-264. doi: 10.1179/174329306x101382