Parametric study and characterization of wire arc additive manufactured steel structures

Kumar, V.; Mandal, Amitava; Das, Alok Kumar; Kumar, Shakti

doi:10.1007/s00170-021-07261-6

Cited by 36 publications

(15 citation statements)

References 28 publications

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“…Accurate modeling of the process is crucial for understanding and controlling RS. For instance, XRD analysis is utilized to identify the grain size observed in the thin strips and ferrite of bainite created due to thermal cycles while dye penetration tests are used to investigate surface defects and corrosion behaviors of WAAM components [66,67,84,85].…”

Section: Residual Stress Measurement Methodsmentioning

confidence: 99%

Review of Measuring Methods of Residual Stress in Wire Arc Additive Manufacturing Products

Gurmesa,

Lemu,

Adugna

et al. 2024

Preprint

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This literature review provides an in-depth exploration of the research conducted on the investigation and measurement of residual stress (RS) in Wire Arc Additive Manufacturing (WAAM) products, particularly focusing on how process parameters influence the phenomenon. RS plays a crucial role in determining the mechanical behavior and structural integrity of WAAM components. This review article gives an understanding of the relationship between process parameters and RS to optimize the WAAM processes and ensure the durability of the final products. It also summarizes key findings, measurement techniques, challenges, and future directions in this evolving field. The review also analyzes a measurement of RS in the products of WAAM as a function of process parameters depending on examining various research studies, techniques, and methodologies employed in their studies. Experimental measuring techniques and numerical analysis of RS to determine the impacts of RS in mechanical response in products of WAAM were discussed. By offering a comprehensive overview of current research trends and insights, this review serves as a valuable resource to guide future investigations, fostering the advancement of WAAM as a robust and efficient manufacturing technology.

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Section: Residual Stress Measurement Methodsmentioning

confidence: 99%

Review of Measuring Methods of Residual Stress in Wire Arc Additive Manufacturing Products

Gurmesa,

Lemu,

Adugna

et al. 2024

Preprint

View full text Add to dashboard Cite

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“…The wear rate of the respective sample is calculated by using equation (4). 42 CWR = 87:4 Where CWR is corrosion wear rate in mm, DW is the weight difference of the sample in milli-gram, before and after the session test, r is the density of the material g cm 23 , A is the wetted surface area of the sample with the salt solution in cm 2 and T is the immersion time in hours.…”

Section: Corrosion and Tribological Analysismentioning

confidence: 99%

Ni-Mo-P coatings on thrust plate of a gear pump to enhance its mechanical, tribological, and corrosion resistance properties

Sharma

Kumar

Das

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part B:

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Thrust plate in an external gear pump is one of the most important element which aligns the rotating gears and prevents the leakage through lateral clearances between rotating and non-rotating surfaces. It acts as a sacrificing element and fails frequently under fluctuating load pressure condition. The present research aims at enhancing the relative mechanical and tribological properties of the sacrificial thrust plate through electroless Ni-Mo-P coatings. Molybdenum (Mo) concentration in the electroless bath were tested for their effects on surface morphology, hardness, phase formation, wear rate, and wettability. A hard and self-lubricating layer (Al, Ni, Si, and Mo phases) on the coated surface was indicated by the compositional analysis performed using EDS and XRD. Results show that the microhardness of the coated surfaces has increased significantly by 149.5% (maximum hardness ~ 183.45 HV0.2) for 32 g L−1 Mo concentration. With 32 g L−1 Mo, the maximum coating thickness and water contact angle were 58 µm and 111°, respectively. The base material’s coefficient of friction was 0.5, whereas it was 0.25, 0.10, 0.06, and 0.03 for the samples made with 8, 16, 24, and 32 g L−1 Mo concentration, respectively. Compared to the uncoated sample, the maximum decrement in corrosion rate was found to be about six to seven times in the coated sample (with 32 g L−1 Mo). As a result, the developed coating surfaces provide hardness, lubricity, hydrophobicity, corrosion, and wear resistance simultaneously. The methodology of surface treatment can be used to modify the surface of critical hydraulic components having significant wear like in case of hydraulic cylinders.

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“…In studying the effect of the GTAW-based WAAM process parameters on the single-layer weld bead geometry, bead roughness and oxidation level of the deposited layers, torch travel speed and arc current were identified as the most influential parameters (Dinovitzer et al , 2019). Some researchers worked on the GMAW-based WAAM process and investigated the effect of welding process parameters, such as the open circuit voltage (OCV) and shielding gas flow rate (SGFR) on the geometry of the deposited single-layer weld bead (Kumar et al , 2021). The study observed a higher OCV produced wider and flatter beads.…”

Section: Introductionmentioning

confidence: 99%

“…However, the development of microstructures along the building direction primarily determines the end properties of WAAM-fabricated components. Researchers have investigated the morphological properties of the WAAM-printed steel structures (Lin et al , 2019; Kumar et al , 2021). The presence of ferrite and pearlite structures in the lower zone comprises the first four deposited layers close to the substrate was observed.…”

Section: Introductionmentioning

confidence: 99%

A critical investigation of the anisotropic behavior in the WAAM-fabricated structure

Kumar,

Mandal

2024

RPJ

Self Cite

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Purpose Wire-arc-based additive manufacturing (WAAM) is a promising technology for the efficient and economical fabrication of medium-large components. However, the anisotropic behavior of the multilayered WAAM-fabricated components remains a challenging problem. Design/methodology/approach The purpose of this paper is to conduct a comprehensive study of the grain morphology, crystallographic orientation and texture in three regions of the WAAM printed component. Furthermore, the interdependence of the grain morphology in different regions of the fabricated component with their mechanical and tribological properties was established. Findings The electron back-scattered diffraction analysis of the top and bottom regions revealed fine recrystallized grains, whereas the middle regions acquired columnar grains with an average size of approximately 8.980 µm. The analysis revealed a higher misorientation angle and an intense crystallographic texture in the upper and lower regions. The investigations found a higher microhardness value of 168.93 ± 1.71 HV with superior wear resistance in the bottom region. The quantitative evaluation of the residual stress detected higher compressive stress in the upper regions. Evidence for comparable ultimate tensile strength and greater elongation (%) compared to its wrought counterpart has been observed. Originality/value The study found a good correlation between the grain morphology in different regions of the WAAM-fabricated component and their mechanical and wear properties. The Hall–Petch relationship also established good agreement between the grain morphology and tensile test results. Improved ductility compared to its wrought counterpart was observed. The anisotropy exists with improved mechanical properties along the longitudinal direction. Moreover, cylindrical components have superior tribological properties compared with cuboidal components.

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Parametric study and characterization of wire arc additive manufactured steel structures

Cited by 36 publications

References 28 publications

Review of Measuring Methods of Residual Stress in Wire Arc Additive Manufacturing Products

Review of Measuring Methods of Residual Stress in Wire Arc Additive Manufacturing Products

Ni-Mo-P coatings on thrust plate of a gear pump to enhance its mechanical, tribological, and corrosion resistance properties

A critical investigation of the anisotropic behavior in the WAAM-fabricated structure

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