Analysis Of Components Produced Using Wire Arc Additive

Ismail, Fatin Nazirah (2019) Analysis Of Components Produced Using Wire Arc Additive. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Wire arc additive manufacturing (WAAM) is one of rapid developing technology in manufacturing industries since it has proven its capability of fulfilling demands of medium – to – large production. WAAM is one of many techniques for 3D printing where a product is produced by adding and depositing material in a layer upon layer manner. It is a combination of welding and additive manufacturing techniques as it used metal welding wire as feedstock and electric arc as the heat source. However, high temperatures in WAAM process leads to defects and quality deformations such as cracking, corrosion, poor surface roughness and more upon the product produced. This is because during WAAM process, as the wall height increases, the heat dissipation to the substrate is slowed down gradually resulting to slow solidification of the molten pool which produces variation of the bead geometry. The purpose of this study is to study on the effect of deposited metal using WAAM with and without an in – process active cooling system of thermoelectric cooling technology. Thermoelectric cooling was installed to the side of the base plate of WAAM setup to regulate the heat dissipation of each layers of deposited metal. A multi – layer with a dimension of 120 mm x 40 mm was fabricated onto a mild – steel plate. Through the tensile test, hardness test and surface roughness analysis, the mechanical properties and microstructure of the fabricated parts by WAAM were explored. Based on the result obtained, the deposited metal without thermoelectric cooling system have better surface roughness and tensile strength compared to deposited metal with thermoelectric cooling system. However, for hardness test, the deposited metal with thermoelectric cooling has proven to have better hardness compared to deposited metal without thermoelectric cooling system. Hence, the proposed method has proven to provide new insight about bead geometry produced using WAAM as it the ability to improve the quality of the fabricated metal parts

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