Microstructural Characteristics of Wire Arc Additive Manufacturing with Inconel 625 by Super-TIG Welding

Cheepu, Muralimohan; Lee, Chang Ik; Cho, Sang Myung

doi:10.1007/s12666-020-01915-x

Cited by 53 publications

(12 citation statements)

References 9 publications

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“…As the voltage increased to 25 V there is a decrease in hardness. Cheepu et al [84] discovered a microstructure with a coarser and less uniform arrangement of grains due to excessive heat input, in comparison to the finer grain structure caused by moderate heat input. This observation clearly supports the theory that excessive heat input produces materials with lower hardness when compared to those created under moderate heat input.…”

Section: Microhardnessmentioning

confidence: 99%

Multi-response optimisation of wire-arc additive manufacturing process parameters for AISI 4130 steel during remanufacturing process

Kachomba,

Mutua,

Obiko

et al. 2024

Mater. Res. Express

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Wire-arc additive manufacturing (WAAM) has emerged as a critical tool for remanufacturing industrial components. A limited understanding of this technique for quality product manufacturing has hindered its utilisation for industrial applications. This study reports on the optimisation of WAAM process parameters for AISI 4130 steel towards remanufacturing of high-quality products for industrial applications. AISI 4130 steel was selected for this study due to its high strength-to-weight ratio, excellent weldability, and suitability for the WAAM process. Taguchi’s Grey Relational Analysis (GRA) used four factors and three levels in the multiple response optimisation process. The study considered process parameters voltage, current, travel speed and gas flow in the gas metal arc welding (GMAW)-based WAAM technique. Analysis of Variance (ANOVA) results show that voltage, travel speed and gas flow significantly affect material deposition. Voltage had the highest significance (31.61%) compared to other parameters. The optimised process parameters were found to be: voltage - 23V, current - 100A, travel speed - 350mm/min, and gas flow - 10L/min. These parameters resulted in tensile residual stresses of 25 ±74 MPa, microhardness of 171.4±12.2 HV0.3, and a relative density of 98.21%. The microstructural analysis reveals existence of predominant ferritic and pearlitic colonies. This is due to compounded thermal stresses during the deposition process and alloy composition resulting in tailored microstructure and mechanical properties. The study provides some insights into the WAAM remanufacturing process for producing highly quality industrial components.

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Section: Microhardnessmentioning

confidence: 99%

Multi-response optimisation of wire-arc additive manufacturing process parameters for AISI 4130 steel during remanufacturing process

Kachomba,

Mutua,

Obiko

et al. 2024

Mater. Res. Express

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“…The dendrite of the previous pass is unevenly remelted by temperature cycles during the multi-pass welding process, and this further acts as a diffusion site for the upcoming pass. 24 In comparison with the sides and edges of the WZ, the formation of cellular structure and columnar structure in the bottom region is more homogenous and symmetric. This is due to the higher transfer of heat to the bottom region giving rise to cellular structures.…”

Section: Microstructure and Microhardness Of Dissimilar Weldmentsmentioning

confidence: 99%

Evolution of microstructure, microhardness, crystallographic texture, and grain size variation in dissimilar joints used in concentrated solar power plants application

Nandhakumar

Kumar

2023

Proceedings of the Institution of Mechanical Engineers, Part L:

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High carbon stainless steel 347H (SS347H) and Inconel 625 (IN625) are high-strength alloys, commonly used in high-temperature applications. These metals are commonly used in the fabrication of concentrated solar power energy storage tanks and pipelines. Construction of such tanks involves dissimilar welding as the primary manufacturing process. The critical factor to consider when joining two different materials is the development of microstructure, as it directly impacts the mechanical characteristics of the joints. According to the available literature, an increase in the heat input (HI) promotes alloying element segregation and susceptibility to weld cracking. Traditional arc welding processes, such as metal inert gas (MIG) welding, produce a higher HI. Therefore, there is a need to develop welding techniques that result in reduced HI. In the present study, a pulse-current MIG (PC-MIG) welding method was employed, utilizing current pulsing to minimize HI during the welding process. The welding was followed by metallographic and mechanical characterization. The microstructural examination found variations in microstructure at different regions. Electron backscatter diffraction analysis shows the crystallographic orientation at different regions. Analysis shows that both SS347H and IN625 have a face-centred cubic austenite structure. The inverse pole figure discloses strong texture formation. The average tensile strength of dissimilar weldments was found to be 479 MPa, while the average hardness value of the fusion zone was measured to be 235 HV. The research indicates that the PC-MIG technique is suitable for joining dissimilar materials with reduced HI, effectively eliminating the risk of cracking and enhancing the efficiency of the joint.

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“…Additionally, in wire arc additive manufacturing, it may affect the resolution by inducing the flow of metal [14], unlike the power ratio used to control hot cracking and dilution in the nuclear power plants. Therefore, H R is considered to be a better parameter for setting the welding conditions due to considering the welding speed and deposition area [18][19][20][21].…”

Section: Oscilaltion Bead Testmentioning

confidence: 99%

Analysis and Characterization of the Weld Pool and Bead Geometry of Inconel 625 Super-TIG Welds

Park

Cheepu²,

Cho³

2020

Metals

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The welding market is changing globally, becoming eco-friendly, robotized and automated. The tungsten inert gas welding (TIG) process is indispensable in industries that require high-quality welds with the absence of spatter and fumes. However, the production rate of TIG welding is very low, which limits its many applications. The present study introduces a novel TIG welding method called super-TIG welding. Super-TIG welding is able to produce a high production rate of welds compared to other fusion welding methods. In super-TIG welding, the novel C-type filler is used, which is different from the conventional TIG welding of circular wire. The relations of the heat input ratio in super-TIG welding to weld pool length and weld bead geometry were measured using the Inconel 625 C-filler. Two types of deposition techniques were used for a bead-on-plate welds, such as stringer beads and oscillation beads. The weld pool and bead geometry measurements are found to be different between stringer beads and oscillation bead techniques. The length of the molten pool and bead size were higher for oscillation beads over the stringer beads. These changes were associated with the difference in heat transfer contact area and bead height.

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Microstructural Characteristics of Wire Arc Additive Manufacturing with Inconel 625 by Super-TIG Welding

Cited by 53 publications

References 9 publications

Multi-response optimisation of wire-arc additive manufacturing process parameters for AISI 4130 steel during remanufacturing process

Multi-response optimisation of wire-arc additive manufacturing process parameters for AISI 4130 steel during remanufacturing process

Evolution of microstructure, microhardness, crystallographic texture, and grain size variation in dissimilar joints used in concentrated solar power plants application

Analysis and Characterization of the Weld Pool and Bead Geometry of Inconel 625 Super-TIG Welds

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