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Preliminary geometrical and microstructural characterization of WC-reinforced NiCrBSi matrix composites fabricated by plasma transferred arc additive manufacturing through Taguchi-based experimentation

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Abstract

Metal matrix composites enhance the wear and corrosion properties of components in heavy-duty industries. This work reports the preliminary effects of process parameters such as current, linear speed, powder flow rate, nozzle angle, powder gas, shield gas, and center gas at the macro-scale and micro-scale of single-track multiple-layer depositions. The use of plasma transferred arc as an additive manufacturing system yields enough energy for a fast solidification rate of the matrix without compromising the carbide in the composite. The results show that the bead height is mainly affected by the powder flow rate, the powder gas, and the travel speed at the macro-scale. The bead width has a close relationship with powder flow rate, powder gas, and current, the latter contributing to the formation of a slumping phenomenon due to heat accumulation. The volumetric deposition is affected by similar parameters to the bead height. At the micro-scale, the process parameters did not show significant carbide changes but demonstrate its homogeneous distribution. The electron microscope observation exhibited the composite’s high quality due to the fast solidification of the process. The results demonstrate that the porosity is mainly affected by the powder flow rate. By understanding the preliminary contribution of process parameters, this manufacturing process can print near net-shaped parts minimizing the post-processing of metal additive manufacturing components. Therefore, this work contributes to implementing a preliminary experimental methodology to understand the deposition process of WC-reinforced composites in plasma transferred arc additive manufacturing.

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Funding

The Natural Sciences and Engineering Research Council of Canada (NSERC) grant numbers RGPIN-2016-04689, CRDPJ 514752-17. Innotech Alberta, under the intern project ATS-2017-IN-028. The Mexican National Council for Science and Technology (CONACYT), under the register 234809 and 440868. Tecnologico de Monterrey, under its program of professor in development.

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Authors and Affiliations

  1. Department of Mechanical Engineering, University of Alberta, Edmonton, AB, T6G 2G8, Canada

    Jose Guadalupe Mercado Rojas, Morteza Ghasri-Khouzani, Tonya Wolfe, Brian Fleck, Hani Henein & Ahmed Jawad Qureshi

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  1. Jose Guadalupe Mercado Rojas
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  2. Morteza Ghasri-Khouzani
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  6. Ahmed Jawad Qureshi
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Contributions

Conceptualization - Ahmed Jawad Qureshi, Tonya Wolfe, and Jose Guadalupe Mercado Roja

Formal analysis - Jose Guadalupe Mercado Rojas and Morteza Ghasri-Khouzani

Investigation - Jose Guadalupe Mercado Rojas

Methodology - Jose Guadalupe Mercado Rojas and Ahmed Jawad Qureshi

Resources - Tonya Wolfe and Hani Henein

Supervision - Ahmed Jawad Qureshi, Tonya Wolfe, and Brian Fleck

Validation - Jose Guadalupe Mercado Rojas, Ahmed Qureshi

Writing: original draft - Jose Guadalupe Mercado Rojas

Writing: review and editing - Ahmed Jawad Qureshi, Tonya Wolfe, and Brian Fleck

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Correspondence to Ahmed Jawad Qureshi.

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Rojas, J.G.M., Ghasri-Khouzani, M., Wolfe, T. et al. Preliminary geometrical and microstructural characterization of WC-reinforced NiCrBSi matrix composites fabricated by plasma transferred arc additive manufacturing through Taguchi-based experimentation. Int J Adv Manuf Technol 113, 1451–1468 (2021). https://doi.org/10.1007/s00170-020-06388-2

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