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Santos, Mathews Lima Dos
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article
Parametric study and response optimization for the wire + arc additive manufacturing of 316LSi via pulsed GMAW
Abstract
Wire + arc additive manufacturing has become a production technology that allows to produce large-sized parts, and components used in heavy-duty industries, spanning from marine to aerospace applications, with high mechanical performance. For additive manufacturing and repair of 316L stainless steel components, heat input control and phase structure evolution are key factors which guide further applications of this material. This can be attained by parameter optimization of the pulsed gas metal arc welding, which can provide control over the aforementioned features of depositions and also regulate metal transfer, reduce spatter generation, and offer structural stability. Through an experimental full-factorial design, this work investigates the processing effects of arc frequency, traverse speed, and wire feed speed on ferrite number and geometric characteristics of multi-layered 316LSi build-ups fabricated using wire + arc additive manufacturing via non-synergic operation of pulsed-gas metal arc welding. The fabrication process was conducted following alternating and successive depositions. It was found that increasing arc frequency negatively impacts ferrite number and height/width ratio, whereas greater values of wire feed speed and traverse speed positively affect both responses. This work also appraises that geometric integrity evaluation should be conducted not only by considering the height/width ratio but also through visualization of deposition process’ stability, as well as verifying the occurrence of spatter and of other discontinuities. The response optimization process was also carried out to manufacture a 74-layer stable wall of nearly 4.12 kg of deposited material, confirming that the optimized condition is appropriate to produce large-sized 316LSi structures.