Optimization of Bead Geometrics for GMAW-Based Wire Arc Additive Manufacturing Using 1.36 Cr-0.5 Mo Steel Metal-Cored Wires
Year: 2025
Type: article
Abstract: Optimizing the process parameters to achieve optimal performance of gas metal arc welding technique of wire arc additive manufacturing using Metalloy 80B2 (1.00-1.50 percent chromium and 0.50 percent molybdenum steel), a gas-shielded metal-cored wire, was the main goal of the current investigation. Depth of penetration (DOP), bead height (BH), and bead width (BW) of bead deposition were examined in relation to changes in input parameters (voltage (22 to 26 V), travel speed (1 to 6 mm/s), and shielding gas composition (CO2-1%, 5%, and 9%). Utilizing the Box Behnken Designs, the set of input variables for the experiment was determined. The significance and sufficiency of the correlation derived from the experiment's results were confirmed through the use of fit statistics and ANOVA. In contrast, to travel speed for BH, the voltage was determined to be a more significant parameter for DOP and BW. Externally studentized residual plots for DOP, BH, and BW were examined, and the results showed that created correlations are legitimate and don't require transformation. The optimum outcomes from Stat-Ease 360 software: DOP = 1.320 mm, BH = 8.381 mm, BW = 8.687 mm for voltage = 26 V, travel speed = 10 mm/s, % of CO2 into gas mixture = 8.317% was achieved with 0.895 desirability. The experimental work for optimum input parameters was conducted and found within the range of results obtained from State Ease 360 software. Experimental results showed that the bead-on-bead material was placed uniformly in a multilayer structure, merged flawlessly, and did not disperse.
Authors: Prerna Shah, Vyomesh Buch, Jay Vora
Language: English
Subfield: Mechanical Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: hybrid
OpenAlex ID: W4410465663