Robotic Welding Tests MIG Standard and CMT+P in Aluminum Alloy 6082-T6 for Optimization of Penetration, Cord Width and Reinforcement

Pascoal, Arlindo; Izeda, A. Eduardo; Cecilio, Vinícius; Mineiro, Nuno; Gonçalves, José; Ribeiro, José Carlos Rabelo

doi:10.3390/icem18-05295

Cited by 4 publications

(9 citation statements)

References 5 publications

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“…On the contrary, the AM technologies such as SLM offer more flexibility in terms of geometric shapes since the deposition of material takes place in multilayers [ 37 ]. The additive manufacturing process can be relatively simple (less technical knowledge is required for its performance), and as a self-autonomous robot-controlled sequence, it may not require a physical human presence [ 3 , 8 ]. The existing expensive AM methods, which yield low surface roughness and poor control of asperities, can be associated with layer-by-layer deposition or re-melting methodologies [ 1 ].…”

Section: Hybrid Productionmentioning

confidence: 99%

“…The range of welding currents to achieve the desired wall thickness was determined by depositing 50 mm long welds to produce walls consisting of 10 layers, as illustrated in Figure 7 . By adjusting the welding current strength, the CMT process controller also automatically determines the wire feed speed and arc voltage [ 2 , 3 ]. The weld surfacing, i.e., WAAM, of 10 layers was sufficient for assessing the stability of the parameters, the walls’ corrugation (grooving), the remelting intensity, and, at the same time, the distance of the torch nozzle from the welding site (10–20 mm); due to the different layers, the height variation do not pose problems with respect to gas shielding.…”

Section: Analysis Of Arc Deposition Parameters (Planning Phase)mentioning

confidence: 99%

“…The largest share of the manufacturing cost is the time of milling, in which most machine hours were spent. By optimizing the welding parameters and improving the surfacing accuracy, the amount of material that needs to be removed by milling could be reduced [ 3 , 4 ]. In this way, the piece could be processed in just one pass, which would reduce processing costs by approximately EUR 1000.…”

Section: Experimental Hybrid Processing Of Alsi5 Work Piecementioning

confidence: 99%

“…Moreover, AM stimulates the possibility of manufacturing cost-effective customized products and hybrid materials for obtaining specific functional properties that might be otherwise unachievable via a single conventional method [ 1 ]. Due to the increased demand for metallic prototypes and components, various metal-printing technologies have also been developed, such as selective laser re-melting (SLM), laser surfacing (LS), electron beam powder and wire re-melting (EBM), and metal inert gas (MIG)/metal active gas (MAG) or wire arc additive manufacturing (WAAM) [ 2 , 3 , 4 , 5 , 6 , 7 ]. These processes utilize a similar concept of melting the metallic precursors in the form of wire or powder directly with the arc or concerted energy beam.…”

Section: Introductionmentioning

confidence: 99%

“…Generally, the parts or surfaces fabricated by arc-welding methods may additionally require post-surface processing and conventional machining to cover for the roughness and heterogeneous distribution of the material at the surfaces. Material losses during these post-finishing processes also contribute to the resource and re-work costs in the conventional welding or arc deposition methods [ 2 , 3 , 8 ].…”

Section: Introductionmentioning

confidence: 99%

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Sustainable Hybrid Manufacturing of AlSi5 Alloy Turbine Blade Prototype by Robotic Direct Energy Layered Deposition and Subsequent Milling: An Alternative to Selective Laser Melting?

et al. 2022

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Additive technologies enable the flexible production through scalable layer-by-layer fabrication of simple to intricate geometries. The existing 3D-printing technologies that use powders are often slow with controlling parameters that are difficult to optimize, restricted product sizes, and are relatively expensive (in terms of feedstock and processing). This paper presents the development of an alternative approach consisting of a CAD/CAM + combined wire arc additive-manufacturing (WAAM) hybrid process utilizing the robotic MIG-based weld surfacing and milling of the AlSi5 aluminum alloy, which achieves sustainably high productivity via structural alloys. The feasibility of this hybrid approach was analyzed on a representative turbine blade piece. SprutCAM suite was utilized to identify the hybrid-manufacturing parameters and virtually simulate the processes. This research provides comprehensive experimental data on the optimization of cold metal transfer (CMT)–WAAM parameters such as the welding speed, current/voltage, wire feed rate, wall thickness, torch inclination angle (shift/tilt comparison), and deposit height. The multi-axes tool orientation and robotic milling strategies, i.e., (a) the side surface from rotational one-way bottom-up and (b) the top surface in a rectangular orientation, were tested in virtual CAM environments and then adopted during the prototype fabrication to minimize the total fabrication time. The effect of several machining parameters and robotic stiffness (during WAAM + milling) were also investigated. The mean deviation for the test piece’s tolerance between the virtual processing and experimental fabrication was −0.76 mm (approx.) at a standard deviation of 0.22 mm assessed by 3D scanning. The surface roughness definition Sa in the final WAAM pass corresponds to 36 µm, which was lowered to 14.3 µm after milling, thus demonstrating a 55% improvement through the robotic comminution. The tensile testing at 0° and 90° orientations reported fracture strengths of 159 and 161.3 MPa, respectively, while the yield stress and reduced longitudinal (0°) elongations implied marginally better toughness along the WAAM deposition axes. The process sustainability factors of hybrid production were compared with Selective Laser Melting (SLM) in terms of the part size freedom, processing costs, and fabrication time with respect to tight design tolerances. The results deduced that this alternative hybrid-processing approach enables an economically viable, resource/energy feasible, and time-efficient method for the production of complex parts in contrast to the conventional additive technologies, i.e., SLM.

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Section: Hybrid Productionmentioning

confidence: 99%

Section: Analysis Of Arc Deposition Parameters (Planning Phase)mentioning

confidence: 99%

Section: Experimental Hybrid Processing Of Alsi5 Work Piecementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 3 more Smart Citations

Sustainable Hybrid Manufacturing of AlSi5 Alloy Turbine Blade Prototype by Robotic Direct Energy Layered Deposition and Subsequent Milling: An Alternative to Selective Laser Melting?

et al. 2022

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Geometries and quality assesment of weld beads in 5052-H32 aluminum alloys joined by semiautomated GMAW through a double fuzzy system

Cavazos Hernández,

Chiñas Sánchez,

Navarro González

et al. 2023

Int J Adv Manuf Technol

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A comprehensive survey on the cold metal transfer process in welding similar and dissimilar materials and for cladding

Shanker

Wattal

2022

Proceedings of the Institution of Mechanical Engineers, Part C:

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The growing use of aluminum in a variety of industries is driving technologists to create practical and effective techniques and processes for joining aluminum alloys. The main aim of this artifact is to critically review and examine the maturity of welding for comparable and differing materials and also for cladding using Cold Metal Transfer. CMT, which stands for Cold Metal Transfer in the acronym, is a modified MIG welding technique. The CMT and its modes are used in similar and dissimilar welding of Al as well as its alloys of 2xxx, 5xxx, 6xxx, and 7xxx series, and with other materials is discussed in detail and compared with other joining methods. The recent advancements in this field with enhanced mechanical properties of Al alloys, as well as high-performance welding techniques, are discussed in this article. The mechanical and microstructural properties of weld like weld strength, microhardness, corrosion behavior, surface morphology, ductility, and fracture mechanism were used to assess the efficiency of the weld. The following aspects of weld bead surface consistency are investigated in terms of bead uniformity along the welding path, bead surface smoothness, and spattering strength. The effort is made to conclude the welding system which is free from all welding flaws, like gas porosity, spattering, and intermetallic formation, resulting in welded joints with the highest mechanical properties. CMT as an advanced welding approach has gained a significant attraction from researchers in investigating it for the cladding process. The geometric and microstructural properties of a clad-like microhardness assessment, and corrosion resistance analyses were used to evaluate the applicability of CMT in the cladding process.

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Robotic Welding Tests MIG Standard and CMT+P in Aluminum Alloy 6082-T6 for Optimization of Penetration, Cord Width and Reinforcement

Cited by 4 publications

References 5 publications

Sustainable Hybrid Manufacturing of AlSi5 Alloy Turbine Blade Prototype by Robotic Direct Energy Layered Deposition and Subsequent Milling: An Alternative to Selective Laser Melting?

Sustainable Hybrid Manufacturing of AlSi5 Alloy Turbine Blade Prototype by Robotic Direct Energy Layered Deposition and Subsequent Milling: An Alternative to Selective Laser Melting?

Geometries and quality assesment of weld beads in 5052-H32 aluminum alloys joined by semiautomated GMAW through a double fuzzy system

A comprehensive survey on the cold metal transfer process in welding similar and dissimilar materials and for cladding

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