Parametric Study and Investigations of Bead Geometries of GMAW-Based Wire–Arc Additive Manufacturing of 316L Stainless Steels

Abstract

Appropriate selection of wire–arc additive manufacturing (WAAM) variables imparts bead geometries with characteristics of multi-layer structures. Thus, the present study aimed to optimize the gas metal arc welding (GMAW)-based WAAM variables of travel speed (TS), wire feed speed (WFS), and voltage (V) for the bead geometries of bead width (BW) and bead height (BH) on an SS 316L substrate. Single-layer depositions were made through a metallic wire of SS 316L by following an experimental matrix of the Box–Behnken design (BBD) technique. Multivariable regression equations were generated for design variables and responses, and ANOVA was used to investigate the feasibility of the obtained regression equations. WFS was the highest contributor affecting the BW, followed by V and TS, while WFS was again the highest contributor affecting the BH, followed by TS and V. Heat transfer search (HTS) optimization was used to attain optimal combinations. The single-objective optimization result showed a maximum bead height and minimum bead width of 6.72 mm and 3.72 mm, respectively. A multi-layer structure was then fabricated by considering an optimization case study, and it showed optimized parameters at a WFS of 5.50 m/min, TS of 141 mm/min, and voltage of 19 V with the bead height and bead width of 5.01 mm and 7.81 mm, respectively. The multi-layered structure obtained at the optimized parameter was found to be free from disbonding, and seamless fusion was detected between the obtained layers of the structure. The authors believe that the present study will be beneficial for industrial applications for the fabrication of multi-layer structures.

Fabrication of Multi-Walled Structure through Parametric Study of Bead Geometries of GMAW-Based WAAM Process of SS309L

“…The TS trend shows that the BW decreased with an increase in TS. This happened because, with higher TS, less metal could be dropped on the same position, leading to less deposition and, thus, smaller BW [ 25 ]. Finally, with higher values of GMR, the BW caused an insignificant change as, at first, it decreased and then increased, negating the changes or uncertainties caused.…”

“…Their results showed that the mechanical properties of the part made from the optimized process parameters were excellent, showing the importance of optimization. Chaudhari et al [ 25 ] studied the effect of WAAM process parameters on a bead’s geometry for single-layer deposition, such as BW or BH, with the variance of parameters such as TS, WFS, and V. They used a Box–Behnken design for singe-layer deposits and found that WFS was the most significant factor for both BW and BH, followed by V and TS. Their study revealed that a multi-layered structure was successfully fabricated at optimized parametric settings at a TS at 141 mm/min, a WFS at 5.50 m/min, and a voltage of 19 V. Natryan et al [ 26 ] used the Taguchi technique to study the effects of TS, welding current, and filler diameter on the quality of welded joints.…”

Implementation of Passing Vehicle Search Algorithm for Optimization of WEDM Process of Nickel-Based Superalloy Waspaloy

“…Analysis of variance (ANOVA) was employed to determine the suitability and importance of the parameters. For ANOVA, 95% of CI was considered, which means p value lowers than 0.05 depict the impact of selected variables to affect the selected response [60,61]. The influence of the machining variables on responses was then investigated, using main effect graphs for individual regression models.…”

Comprehensive Investigation of Hastelloy C-22 Powder Weld Overlay on SA 240 Type 316L Using Laser Beam Welding for Enhanced Performance

“…In recent years, there has been a growing trend towards the application of Hastelloy C-22 weld overlay on SA 240 Type 316L in various industries, including petrochemicals. Due to the greater heat resistance properties of stainless steels, they are largely preferred in chemical, oil, gas, and petrochemical sectors [39,40]. This trend is driven by the need for materials that can withstand highly corrosive environments, maintain structural integrity, and reduce maintenance costs [41].…”