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Parametric study and response optimization for the wire + arc additive manufacturing of 316LSi via pulsed GMAW

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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.

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Funding

This work was supported by multiuser funding of Fundação de Amparo à Ciência e Tecnologia do Estado de Pernambuco (FACEPE) under grant number APQ-0964–3.03/21. TFAS was supported with a scientific productivity scholarship (grant number 304741/2020–5) by Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq). JPO was funded with national funds by FCT—Fundação para a Ciência e a Tecnologia, I.P., in the scope of the projects LA/P/0037/2020, UIDP/50025/2020, and UIDB/50025/2020 of the Associate Laboratory Institute of Nanostructures, Nanomodelling and Nanofabrication – i3N. This study was further supported by Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES), Financiadora de Estudos e Projetos (FINEP), and Agência Nacional do Petróleo, Gás Natural e Biocombustíveis (ANP/Petrobras).

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Authors and Affiliations

  1. Department of Mechanical Engineering, Universidade Federal de Pernambuco, Rua da Inovação, S/N, Cidade Universitária, Recife, 50740-540, Brazil

    Guilherme Gadelha de Sousa Figueiredo, Ivan Bezerra de Mello Picchi, Mathews Lima dos Santos & Tiago Felipe de Abreu Santos

  2. Brazilian Institute for Material Joining and Coating Tecnologies (INTM), Universidade Federal de Pernambuco, Rua da Inovação, S/N, Cidade Universitária, Recife, 50740-540, Brazil

    Guilherme Gadelha de Sousa Figueiredo, Ivan Bezerra de Mello Picchi, Mathews Lima dos Santos & Tiago Felipe de Abreu Santos

  3. Department of Mechanical Engineering, Universidad de Antioquia, Research Group GEA, Medellin, Colombia

    Edwar Andrés Torres López

  4. CENIMAT/I3N, Department of Materials Science, NOVA School of Science and Technology, Universidade NOVA de Lisboa, 2829-516, Caparica, Portugal

    João Pedro Oliveira

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  1. Guilherme Gadelha de Sousa Figueiredo
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Contributions

G.G. Sousa: contributed to the development of experimental setup, measurements acquisition, interpretation of numerical data, graphical planning, and framework.

I.B.M. Picchi: contributed to the development of experimental setup, analysis and interpretation of numerical data, graphical planning, and framework.

M.L. Santos: contributed to the development of experimental setup, measurements acquisition, interpretation of numerical data, graphical planning, and framework.

E.A.T. Lopez: contributed to delimitation of the research topic, interpretation of numerical data, graphical planning, and framework.

J.P. Oliveira: contributed to interpretation of numerical data, manuscript translation, graphical planning, and framework.

T.F.A. Santos: contributed to delimitation of the research topic, interpretation of numerical data, graphical planning and framework.

All the authors contributed to manuscript writing and reviewing.

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Correspondence to Tiago Felipe de Abreu Santos.

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de Sousa Figueiredo, G.G., de Mello Picchi, I.B., Lima dos Santos, M. et al. Parametric study and response optimization for the wire + arc additive manufacturing of 316LSi via pulsed GMAW. Int J Adv Manuf Technol 129, 3073–3092 (2023). https://doi.org/10.1007/s00170-023-12470-2

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