E120C-GH4 METAL ÖZLÜ VE ER120S-G MASİF TELİN TEL ARK EKLEMELİ İMALATI (WAAM) İÇİN KARŞILAŞTIRMALI PROSES PARAMETRE OPTİMİZASYONU
Year 2024,
, 2013 - 2028, 02.10.2024
Mustafa Harman
,
Cemil Çetinkaya
,
Oğuzhan Yılmaz
,
Nevzat Bol
Abstract
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.
Ethical Statement
Bu makalenin yazar(lar)ı çalışmalarında kullandıkları materyal ve yöntemlerin etik kurul izni ve/veya yasal-özel bir izin gerektirmediğini beyan ederler.
Supporting Institution
GAZİ ÜNİVERSİTESİ BİLİMSEL ARAŞTIRMA PROJELERİ KOORDİNASYON BİRİMİ
Project Number
FDK-2022-8106
Thanks
Intecro Robotik A.Ş'ye sunmuş olduğu makine parkı ve tezgah altyapısı için teşekkür ederiz.
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Comparative Process Parameter Optimization For Wire Arc Additive Manufacturing (WAAM) of E120C-GH4 Metal Cored and ER120S-G Solid Wire
Year 2024,
, 2013 - 2028, 02.10.2024
Mustafa Harman
,
Cemil Çetinkaya
,
Oğuzhan Yılmaz
,
Nevzat Bol
Abstract
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.
Project Number
FDK-2022-8106
References
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- [2] Güler, S., Serindağ, H.T., and Çam, G., “Wire Arc Additive Manufacturing (WAAM): Recent Developments and Prospects," Engineer and Machinery, 63 (706), 82–116 (2022).
- [3] Çam, G., and Günen, A. “Challenges and opportunities in the production of magnesium parts by directed energy deposition processes”, Journal of Magnesium and Alloys, 12, 1663-1686 (2024).
- [4] Wengang Z., Wu N., and Zhou W., “Effect of interpass temperature on wire arc additive manufacturing using high-strength metal-cored wire," Metals, 12(212), 1–15, (2022).
- [5] Kumar, A.; Maji, K., “Selection of process parameters for near-net shape deposition in wire arc additive manufacturing by genetic algorithm." Journal of Materials Engineering and Performance, 29, 3334–3352 (2020).
- [6] Tomaz, I.d.V., Colaço F.H.G., Sarfraz S., Pimenov D.Y., Gupta M.K., and Pintaude G., “Investigations on quality characteristics in gas tungsten arc welding process using an artificial neural network integrated with a genetic algorithm," The International Journal of Advanced Manufacturing Technology, 113, 3569–3583, (2021).
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- [9] [9] Lee S.H., “Optimization of cold metal transfer‐based wire arc additive manufacturing processes using gaussian process regression," Metals, 10, 461, (2020).
- [10] Szost, B.A., Terzi, S.; Martina, F., Boisselier, D., Prytuliak, A., Pirling, T., Hofmann, M., Jarvis, D.J., “A comparative study of additive manufacturing techniques: residual stress and microstructural analysis of CLAD and WAAM-printed Ti-6Al-4V components", Materials and Design, 89, 559–567 (2016).
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- [15] Günen A., Gürol U., Koçak M., and Çam G., “Investigation into the influence of boronizing on the wear behavior of additively manufactured Inconel 625 alloy at elevated temperature," Progress in Additive Manufacturing, 8, 1281–1301 (2023).
- [16] Günen A., Gürol U., Koçak M., and Çam G., “A new approach to improve some properties of wire arc additively manufactured stainless steel components: simultaneous homogenization and boriding," Surface & Coating Technology, 460, 129395 (2023).
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- [18] Ceritbinmez F., Günen A., Gürol U., and Çam G., “A comparative study on the drillability of Inconel 625 alloy fabricated by wire arc additive manufacturing," Journal of Manufacturing Processes, 89, 150–169, (2023).
- [19] Internet: Total Materia. The world's most comprehensive material database. Web: https://www.totalmateria.com/page.aspx?ID=Home&LN=TR. Last access date: June 25, (2024).
- [20] Küçük Z., "Comparison of Tangential and Orthogonal Turning-Milling Methods Using Taguchi Experimental Design Method," Master's Thesis, Fırat University Institute of Science and Technology, (2017).
- [21] Roy R.K., "A primer on the Taguchi Method," Ellen J. Kehoe, Society of Manufacturing Engineers, 2009942461, United States of America (2010).
- [22] Nas, E., and Özbek, N.A., "Optimization of the machining parameters in turning of hardened hot work tool steel using cryogenically treated tools," World Scientific Publishing Company, 27: 1–14 (2019).
- [23] Kapçak E., "Optimization of welding process parameters using the Taguchi method: an application for nut welding operation," Master's Thesis, Balıkesir University Institute of Science and Technology, (2022).
- [24] Callister D.W., Rethwisch D.G., "Materials Science and Engineering (Trans. K.General)", Nobel Academic Publishing Education Consultancy Trade Limited Company, Ankara: 343–390 (2014).
- [25] Wen C., Wang Z., Deng X., Wang G., Devesh R., Misra K. “Effect of Heat Input on the Microstructure and Mechanical Properties of Low Alloy Ultra-High Strength Structural Steel Welded Joint”, Steel research int., 89, (2018).
- [26] Almeida P., “Innovative process model of Ti–6Al–4V additive layer manufacturing using cold metal transfer (CMT)”, The 21st annual international solid freeform fabrication symposium, vol. 2010, University of Texas at Austin (2010).
- [27] Cadiou S., Courtois M., Carin M., Berckmans W., and Le Masson P., “3D heat transfer, fluid flow, and electromagnetic model for cold metal transfer wire arc additive manufacturing (Cmt-Waam)”, Additive Manufacturing, 36, 101541, (2020).
- [28] Ayarkwa K.F., Williams S., and Ding J., “Investigation of pulse advance cold metal transfer on aluminum wire arc additive manufacturing," International journal of rapid manufacturing, 5 (1), 44–57 (2015).
- [29] Trinh, N.Q., Tashiro, S., Suga, T., Kakizaki, T., Yamazaki, K., Lersvanichkool, A., Bui, H.V., and Tanaka, M. “Metal transfer behavior of metal-cored arc welding in pure argon shielding gas,” Metals, 12, 1577 (2022).
- [30] XU X., “Wire + Arc Additive Manufacture of New nd Multiple Materials," Doctoral Thesis, Cranfield University School of Aerospace, Transport, and Manufacturing (2017).
- [31] Kara, S., and Korkut, M.H., "Investigation of the Effect of Heat Treated After Welding on Strength of Joints in Used Armored Combat Vehicles," Journal of Defense Sciences, 11 (2), 159–171 (2012).
- [32] Tülbentçi, K., “MIG-MAG Gas Welding Method”. Arctech Welding Electrodes Publication, Publication No. 2, İstanbul, 1-55. (1998).
- [33] Güner M., "Examining the effect of electrode type (bare wire or flux-cored wire) on weld bead properties in MAG welding," Master's Thesis, Yıldız Technical University, Institute of Science and Technology, (2007).
- [34] Işık A.O., "Examining the Effect of Electrode Type on Weld Seam Properties in MAG Welding," Master's Thesis, Yıldız Technical University Institute of Science and Technology, (2014).
- [35] Sanyal S., Chandra S., Kumar S., and Roy G.G., “An Improved Model of Cored Wire Injection in Steel Melts," ISIJ International, 44, 1157–1166, (2004).
- [36] Özkan, E., "Characterization of the Submerged Arc Welding Flux and Flux Cored Wire Combination, Which Fulfills The Required Mechanical and Metallurgical Properties, For Industrial Applications," Doctoral Thesis, Ege University Institute of Science and Technology, (2015).
- [37] Adonyi, Y., "HAZ Properties in High-Performance Steel Solid-State Welds," CWA Conference, 1-20, Longview (2014).
- [38] Internet: TWI Training & Examination Services EWF/IIW Diploma Course Presentation Web: https://slideplayer.com/slide/1568314/.Last access date: 03.04.(2024).
- [39] Vora J., Parikh N., Chaudhari R., Patel V.K., Paramar H., Pimenov D.Y., and Giasin K., "Optimization of Bead Morphology for GMAW-Based Wire-Arc Additive Manufacturing of 2.25 Cr-1.0 Mo Steel Using Metal-Cored Wires," Applied Sciences, 12, 5060. (2022).
- [40] Chaudhari R., Parikh N., Khanna S., Vora J., and Patel V., "Effect of multi-walled structure on microstructure and mechanical properties of 1.25Cr-1.0Mo steel fabricated by GMAW-based WAAM using metal-cored wire," Journal of Material Research and Technology, 21: 3386–3396, (2022).
- [41] Internet: BÖHLER X 90-IG Solid wire, low-alloyed, high strength. https://rebels-grup.ro/wp-content/uploads/2020/10/Bohler_X90-IG.pdf. Last access date: June 22, (2024).
- [42] Internet: BÖHLER alform® 900 MC metal-cored wire. https://www.voestalpine.com/welding/uk-en/company/news-and-events/welding-consumables-for-crane-and-lifting/ . Last access date: (2024).
- [43] Internet: Manufacture process of seamless cored wire: Voestalpine Böhler Welding https://www.youtube.com/watch?v=4CdbXF_T5ss. Last access date: June 22, (2024).
- [44] Akkurt, A., “Waterjet Cutting Systems and Assessment of Their Industrial Applications," Journal of Polytechnic, 7(2), 129–139 (2004).
- [45] Harman M., Ada H., and Çetinkaya C., "Introduction of Weldability of High Strength Steels Using Different Welding Methods," Master's Thesis, Gazi University Graduate School of Natural and Applied Sciences (2019).
- [46] Ada, H., “Optimisation Of The Welding Parameters Of Joints Of Api Pipes With Taguchi Method," Doctoral Thesis, Gazi University Institute of Science and Technology, Ankara, (2017).
- [47] Bhadeshıa, H. K. D. H. Bainite in steels transformations, microstructure, and properties. London: Cambridge University Pess, (2001).
- [48] Lin Z., Goulas C., Ya W., and Hermans M.J.M., “Microstructure and mechanical properties of medium carbon steel deposits obtained via wire and arc additive manufacturing using metal-cored wire metals," Metals, 9, 673 (2019).
- [49] Gürol U., Dilibal S., Turgut B., and Koçak M., "Characterization of a low-alloy steel component produced with a wire arc additive manufacturing process using metal-cored wire," Materials Testing, 64(6): 755–767, (2022).
- [50] Harati, E., Jose, B., & Igestrand, M., "Wire arc additive manufacturing using high-strength steel tubular and solid wires," Welding International, 38(5), 329–334, (2024).
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