Non-Destructive Testing Inspection for Metal Components Produced Using Wire and Arc Additive Manufacturing

Serrati, Douglas S. M.; Machado, Miguel A.; Oliveira, J.P.; Santos, Telmo G.

doi:10.3390/met13040648

Cited by 4 publications

(1 citation statement)

References 65 publications

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“…Areas with incomplete penetration and a lack of connection are referred to as incomplete joint penetration. Several factors can contribute to incomplete weld penetration, including insufficient weld heat, improper weld design, or inadequate control of weld parameters [27].…”

Section: Radiography Testing (Rt)mentioning

confidence: 99%

Integrated Assessment of MIG Welding Parameters on Carbon Steel using RSM Optimisation

Junita Mohd Said,

Faiz Mohd Turan,

Norazlianie Sazali

2023

ARAM

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This study examined how parameter optimisation in MIG welding affects material properties, weld quality, flexural strength, and weld bead geometry using an experimental design. Structural testing reveals that weld pool imperfections, especially in welded joints, often lead to metal failure. Incorrect selection of welding parameters, material weldability, and metal forming contribute to defects and necessitate post-treatment. The study aims to minimize weld defects and maximize material strength in welded parts using a quadratic second-order regression model to predict optimal process parameters. The chosen JIS G3131 hot-rolled carbon steel material is commonly used in automotive parts, is cost-effective, and can be easily welded. The welding process is MIG buttweld according to AWS 1.1 standards. The tests match the RSM design's 3-by-3 orthogonal array. The process parameters are welding current, arc voltage, and welding speed. The responses are bead height, bead width, penetration, and flexural strength. NDT X-ray radiography detects flaws in weld pools. The welded connection's durability is determined with a three-point bending test. Experiments are conducted to find the best input parameters with 95% confidence. This study also uses an experimental design based on an orthogonal array and an analysis of variance (ANOVA). Contribution to factors and regression analysis. The predicted flexural strength was 903.1 MPa, with a 0.66% error compared to the experimental value of 897 MPa. Predicted values for weld penetration, bead width, and bead height are 3.01, 9.45, and 2.04. In the RT inspection test, the test sample with the optimum parameters had no defects in the welded joint. The optimal parameter values for the regression analysis of the RSM combination are 115, 20, and 18 for current, speed, and voltage. Confirmation tests for DT and NDT were performed to validate the optimal parameter settings. This research shows that optimizing process parameters for welded products improves weld geometry and flexural strength. This method is widely used and valuable in metal fabrication.

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Section: Radiography Testing (Rt)mentioning

confidence: 99%

Integrated Assessment of MIG Welding Parameters on Carbon Steel using RSM Optimisation

Junita Mohd Said,

Faiz Mohd Turan,

Norazlianie Sazali

2023

ARAM

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Vision based process monitoring in wire arc additive manufacturing (WAAM)

Franke,

Heinrich,

Reisch

2024

J Intell Manuf

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A stable welding process is crucial to obtain high quality parts in wire arc additive manufacturing. The complexity of the process makes it inherently unstable, which can cause various defects, resulting in poor geometric accuracy and material properties. This demands for in-process monitoring and control mechanisms to industrialize the technology. In this work, process monitoring algorithms based on welding camera image analysis are presented. A neural network for semantic segmentation of the welding wire is used to monitor the working distance as well as the horizontal position of the wire during welding and classic image processing techniques are applied to capture spatter formation. Using these algorithms, the process stability is evaluated in real time and the analysis results enable the direction independent closed-loop-control of the manufacturing process. This significantly improves geometric fidelity as well as mechanical properties of the fabricated part and allows the automated production of parts with complex deposition paths including weld bead crossings, curvatures and overhang structures.

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Non-destructive testing of metal-based additively manufactured parts and processes: a review

Rao,

Leong Sing,

Liu

et al. 2023

Virtual and Physical Prototyping

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Non-Destructive Testing Inspection for Metal Components Produced Using Wire and Arc Additive Manufacturing

Cited by 4 publications

References 65 publications

Integrated Assessment of MIG Welding Parameters on Carbon Steel using RSM Optimisation

Integrated Assessment of MIG Welding Parameters on Carbon Steel using RSM Optimisation

Vision based process monitoring in wire arc additive manufacturing (WAAM)

Non-destructive testing of metal-based additively manufactured parts and processes: a review

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