Abstract: Shaped Metal Deposition (SMD) in additive layered manufacturing technique is a promising alternative to traditional manufacturing used for manufacturing large, expensive metal components with complex geometry in addition to producing free structures by building materials in a layer by layer technique. The present paper is a comprehensive review of the literature and the latest rapid manufacturing technologies of the SMD technique. The aim of this paper is to comprehensively review the most prominent facts that researchers have dealt with in the SMD techniques especially those associated with the cold wire feed. The intent of this study is to review the literature presented on metal deposition processes and their classifications, including SMD process using Wire + Arc Additive Manufacturing (WAAM) which divides into wire + tungsten inert gas (TIG), metal inert gas (MIG), or plasma. This literary research presented covers extensive details on bead geometry, process parameters and heat input or arc energy resulting from the deposition process in both cases MIG and Tandem-MIG in SMD process. Furthermore, SMD may be done using Single Wire-MIG (SW-MIG) welding and SMD using Double Wire-MIG (DW-MIG) welding. The present review shows that the method of deposition of metals when using the DW-MIG process can be considered a distinctive and low-cost method to produce large metal components due to high deposition rates as well as reduce the input of high temperature generated during deposition and reduce the distortions. However, the accuracy and surface finish of the MIG-SMD are less as compared to electron and laser beam.
Abstract: The heat flow in weldment changes its nature from 2D to 3D with the increase in plate thickness. For welding of thicker plates the heat loss in thickness direction increases the cooling rate of plate. Since the cooling rate changes, the various bead parameters like bead penetration, bead height and bead width also got affected by it. The present study incorporates the effect of variable plate thickness on penetration and bead width. The penetration reduces with increase in plate thickness due to heat loss in thickness direction for same heat input, while bead width increases for thicker plate due to faster cooling.
Abstract: The present paper aims to investigate the effects of the welding process parameters and cooling state on the weld bead geometry, mechanical properties and microstructure characteristics for weldments of AISI 304L stainless steel. The welding process was carried out using TIG welding with pulsed/non-pulsed current techniques. The cooling state was introduced as an input parameter to investigate the main effects on the structure morphology and thereby the mechanical property. This paper clarifies microstructure- mechanical property relationship of the welded specimens. In this work, the selected pulse frequency levels were 5-500 Hz in order to study the effect of low and high frequencies on the weldment characteristics using filler metal of ER 308LSi. The key findings of this work clarified that the pulse frequency has a significant effect on the breaking of the dendrite arms during the welding process and so strongly influences on the tensile strength and microhardness. The cooling state also significantly affects on the microstructure texture and thereby, the mechanical properties. The most important factor affects the bead geometry and aspect ratio is the travel speed and pulse frequency.
Abstract: In this study, the butt welding of the commercial AZ31 magnesium alloy sheets have been carried out by using Tungsten Inert Gas (TIG) welding process with alternative and pulsed current. Welded samples were examined with regards to hardness and microstructure. Despite some recent developments in welding of magnesium alloys, they have some problems such as porosity, hot cracking, oxide formation and so on. Samples of the welded parts have undergone metallographic and mechanical examination. Porosities and homogeneous micron grain oxides were rarely observed. Orientations of the weld microstructure in terms of heat transfer also were rarely observed and equiaxed grain morphology was dominant grain structure as in the base metal. As results, fusion zone and few locations of the HAZ of the welded samples have shown twin’s grains. Hot cracking was not observed for any samples. Weld bead geometry of the welded samples were evaluated as normal according to welding parameters. In the results, conditions of alternative and pulsed current and the samples were compared to each other with regards to microstructure and hardness.
Abstract: Today automobile and aerospace industries realise Laser Beam Welding for a clean and non contact source of heating and fusion for joining of sheets. The welding performance is mainly based on by the laser welding parameters. Some concepts related to Artificial Neural Networks and how can be applied to model weld bead geometry and mechanical properties in terms of equipment parameters are reported in order to evaluate the accuracy and compare it with traditional modeling schemes. This review reveals the output features of Titanium and Aluminium weld bead geometry and mechanical properties such as ultimate tensile strength, yield strength, elongation and reduction of the area of the weld using Artificial Neural Network.
Abstract: Gas Metal Arc Welding (GMAW) processes is an
important joining process widely used in metal fabrication
industries. This paper addresses modeling and optimization of this
technique using a set of experimental data and regression analysis.
The set of experimental data has been used to assess the influence
of GMAW process parameters in weld bead geometry. The
process variables considered here include voltage (V); wire feed
rate (F); torch Angle (A); welding speed (S) and nozzle-to-plate
distance (D). The process output characteristics include weld bead
height, width and penetration. The Taguchi method and regression
modeling are used in order to establish the relationships between
input and output parameters. The adequacy of the model is
evaluated using analysis of variance (ANOVA) technique. In the
next stage, the proposed model is embedded into a Simulated
Annealing (SA) algorithm to optimize the GMAW process
parameters. The objective is to determine a suitable set of process
parameters that can produce desired bead geometry, considering
the ranges of the process parameters. Computational results prove
the effectiveness of the proposed model and optimization
procedure.
Abstract: Bead-on-plate welds were carried out on AISI 316L
(N) austenitic stainless steel (ASS) using flux cored arc welding
(FCAW) process. The bead on plates weld was conducted as per L25
orthogonal array. In this paper, the weld bead geometry such as depth
of penetration (DOP), bead width (BW) and weld reinforcement (R)
of AISI 316L (N) ASS are investigated. Taguchi approach is used as
statistical design of experiment (DOE) technique for optimizing the
selected welding input parameters. Grey relational analysis and
desirability approach are applied to optimize the input parameters
considering multiple output variables simultaneously. Confirmation
experiment has also been conducted to validate the optimized
parameters.
Abstract: In this research work, investigations are carried out on
Continuous Wave (CW) Nd:YAG laser welding system after
preliminary experimentation to understand the influencing parameters
associated with laser welding of AISI 304. The experimental
procedure involves a series of laser welding trials on AISI 304
stainless steel sheets with various combinations of process parameters
like beam power, beam incident angle and beam incident angle. An
industrial 2 kW CW Nd:YAG laser system, available at Welding
Research Institute (WRI), BHEL Tiruchirappalli, is used for
conducting the welding trials for this research. After proper tuning of
laser beam, laser welding experiments are conducted on AISI 304
grade sheets to evaluate the influence of various input parameters on
weld bead geometry i.e. bead width (BW) and depth of penetration
(DOP). From the laser welding results, it is noticed that the beam
power and welding speed are the two influencing parameters on
depth and width of the bead. Three dimensional finite element
simulation of high density heat source have been performed for laser
welding technique using finite element code ANSYS for predicting
the temperature profile of laser beam heat source on AISI 304
stainless steel sheets. The temperature dependent material properties
for AISI 304 stainless steel are taken into account in the simulation,
which has a great influence in computing the temperature profiles.
The latent heat of fusion is considered by the thermal enthalpy of
material for calculation of phase transition problem. A Gaussian
distribution of heat flux using a moving heat source with a conical
shape is used for analyzing the temperature profiles. Experimental
and simulated values for weld bead profiles are analyzed for stainless
steel material for different beam power, welding speed and beam
incident angle. The results obtained from the simulation are
compared with those from the experimental data and it is observed
that the results of numerical analysis (FEM) are in good agreement
with experimental results, with an overall percentage of error
estimated to be within ±6%.