Additive manufacturing

1. 2020 1441
Prepared by:
Hassan Jasib Khudhair
B.Sc. Mech. Eng.
Supervised by:
Prof. Dr. ADNAN A. UGLAAL-OMAR
Ph.D. Mech. Eng.
DESIGNING, FABRICATING, AND
CONTROLLING OF SHAPED METAL
DEPOSITION SYSTEM IN ADDITIVE
MANUFACTURING TECHNOLOGY

2. Introduction

3. In the aerospace industry, there are many distinctive and
expensive components of complex shapes produced through heavy
metals and alloys with high specifications. These components are
often manufactured in traditional manufacturing methods, (casting,
forging, machining, etc.). The production of these parts is usually
accompanied by large-scale operations in addition to finishing
processes and the cost of mold and tools. At present, there is an
urgent need to develop promising alternative techniques to fabricate
metal parts that are used in important areas.
General Introduction

4. One of the new alternative approaches that have aroused the
interest of many industries is the shaped metal deposition (SMD)
technique, which is considered one of the interesting alternatives and
is considered one of the technologies of additive manufacturing
(AM) or so-called rapid metal manufacturing (RMM) process. This
technique is used to produce new components, repair parts that have
been subjected to failure because of mechanical or other processes.
In addition, it has the ability to fabricate complex components of
complex shapes, sizes and geometrical cavities, and easy automatic
path planning as well as the production of very small sizes smaller
than the conventional methods common .
General Introduction
Shaped Metal Deposition (SMD)
Additive Manufacturing

5. Literature Review

6. Clark, Zhang et al, Yilmaz & Ugla, Wang [50], [24],[73], [29] In these
studies, researchers used SW-SMD. They studied the effect of process
parameters on mechanical and microscopic properties. The results showed
that the process variables greatly influence the mechanical properties and the
results showed that the microscopic structure of the samples was in the form
of dendritic structure.
SMD Using Single Wire SW-SMD

7. SMD Using Double Wire DW-SMD
Li et al. [104] suggested the DW-GMAW a variation of conventional GMAW to
1- Decrease the base metal heat input and
2- maintain the wire melting current regular through presenting (GTAW) bypass
torch.
Wu et al. [106] indicated that the torches' relative position acquired a great
effect on the balance of the arcs and metal deposition in the DW-GMAW
technique.
Yang et al. (2016) [105] investigated developing features within GMAW
multi-layer, single-bead AM by Double Torch (DW-GMAW) and supplies a
theoretical foundation for its technique.

8. Research Gaps
it is obvious that there is a gap in the research studies concerned
using externally cold wire as a minor feed way to the deposition
area. Thus, a new technology for metal deposition can be
obtained through system consists of a cold feed wire (filler wire)
equip through an external device by wire guide plus MIG-
welding.

9. The main purpose of this work is:
• Design, fabrication and control of computer aided double wire deposition
machine (CADWDM). It is a machine controlled by a computer with a
MIG welding machine equipped with cold feed wire to study the whole
process parameters and fabricating net or near-net different components
directly from CAD data with the minimum time consumed in programming
by utilizing the Matlab program to control a robotic arm.
Research Aims and Objectives
• Investigate the process parameters( current (I), Travel speed (TS), Wire
Feed (W.F) ) by analyzing the influence of the main parameters on the weld
bead geometry and quality of the deposited parts. Build the process window
for the main parameters of the deposition process. Calculation the removed
layer material from deposited parts.

10. Also, optimize the process parameters and find the more suitable
parameter for deposition process by using the minitype program.
• Study the deposition path pattern Strategy of the CADWDM
system and show the CADWDM system capabilities and
limitations. In addition to study the relationship between the
process parameters and weld bead geometry.
• Study the characterizes microstructures, mechanical properties
and interpass temperature in both (without cold wire feed, low
cold wire feed, and high cold wire feed) of the deposited
SS309LSi stainless steel parts.
Research Aims and Objectives

11. Designing, Experimental
setup, and Materials &
Method

12. A three-axis system was designed and manufactured to
facilitate SMD operations. Initially, a feasible design of the
proposed CADWD machine had been prepared. The design had
been carried out according to the valid standards. The
CADWDM is actuated with three stepper motors, which
connected along with x-, y-, and z-directions. The maximum
working area is (450 x 750 x 200) mm3. Machine design carried
out using Auto CAD program and then it was simulated through
ANSYS workbench program.
Design the System

13. *

14. *

15. Experimental Setup
*

16. Experimental Setup
*
(4) Control unite (6) Hardware structure(5) PC-Interface program

17. Experimental Setup
*

18. Experimental Setup
*

19. Experimental Setup
*

20. Materials and Method
The chemical composition of the filler material and the substrate
Materials C SI Mn S P Mo Ni Cr Cu Fe
309L 0.03% 0.9% 1.3% --- --- 0.1% 12.5% 24% 0.1% Rem
Substrate 0.1
Max
0.03-
0.15
0.2-
0.45
0.04 0.04 ----- ----- ----- ----- Rem
The consumable electrode of 1.2mm diameter was stainless steel 309L. Its grade was
selected according to AWS A5.22 specification, so the wire grade is “E309LTI-1/T1-4”
FLUX-CORE- Automatic Protected. Stainless steel have good strength and high
corrosion resistance and can use thermal power plant and medical industry, so is suitable
for SMD process.

21. Polarity DCRP
Arc length (L) 1mm
Feeding angle 30 Degree
Torch angle 90 Degree
Wire stick-out 15 mm
Constant Parameters used for MIG-
SMD.

22. Preliminary-experiments for single-
layer to find the process model
Input parameter
(symbol)
Units Levels
1 2 3 4 5
Welding Current
(I)
(A) 160 190 210
Travel speed
(TS)
(mm/sec) 2 3 4 5
Wire feed speed
(W.F.S)
(m/min) 2 3 4 5 6
*Cold wire feed was kept as constant (2m/min).

23. SMD Process Window
(1) Droplets occurs, (2) Excessive melting and sometimes
Droplets may appear,(3) Stable process and smooth bead
deposition, (4) Stubbing, humping may occur and Large droplets
adhering to each other may appear, (5) Stubbing and humping
occur, and (6) Wavy and Whirling occur.

24. (a) Dripping formation, (b) Stubbing bead deposition,
(c) excessive melting, humping, and whirling, and (d)
Stable and smooth bead deposition.

25. Identified factors with levels for Multi-
Layer experiments (DOE)
* Wire feed come from the welding machine. ** Cold wire feed come from an
external nozzle device.
Input parameter
(Symbol)
Units Levels
1 2 3
Welding Current (I) (A) 160 190 210
Travel speed (TS) (mm/sec) 2 3 4
WIRE-Ratio (W.R)
(W.F1
* /W.F2
**)
1.5 2 2.5

26. Experimental layout of parameters
with their levels.
This experiment was planned using the DOE methodology. The Taguchi ( L9 ) method was
used to determine welding parameters with the best optimal welding bead geometry.
Exp. No. I (A) TS (mm/sec) WR (m/min)
1 160 2 1.5
2 160 3 2
3 160 4 2.5
4 190 2 2
5 190 3 2.5
6 190 4 1.5
7 210 2 2.5
8 210 3 1.5
9 210 4 2

27. Mechanical Test-Hardness Test

28. Quaser 25 Tensile TEST Device
Mechanical Test-Tensile Test

29. Interpass Temperature
Recording
Data Logger Device

30. Results

31. Ansys Result- Total
Deformation

32. Ansys Result- Total Deformation (video)

33. Ansys Result- Total
Deformation

34. Ansys Result- Total
Deformation

35. Ansys Result- Equivalent
Stress

36. Ansys Result- Equivalent
Stress

37. Ansys Result- Equivalent
Stress

38. Ansys Result- Equivalent
Stress

39. Ansys Result- Safety Factor
The allowable stress of the machine can be obtained
by dividing the yield strength by the machine safety
factor (280 Mpa / 15 = 18.67 Mpa). Then the
Machine in safe side design

40. Start
CAD Drawing
Set:
points of shape
Set:
H : Height of Layers
( OR)
L : Number of Layers
Create Shape
Construct wall for shape
Generate Trajectory for
motion
Test by Animate motion
Save result paths (File of
points with time)
Connect Machine (CAM) Set Speed of operation Set Zero Position by JOG Load Saved file
RUN (motion in real
system)
End
CAD-CAM Process

41. Path Planning Strategies

42. Path Planning Strategies

43. *

44. *
Source DOF Seq.
SS
Adj.
MS
F-
value
P-
value
Percent
contributi
on
I 1 2.163 2.163 4.36 0.091 15.88%
TS 1 3.039 3.0388 6.12 0.056 22.30%
WR 1 5.940 5.9401 11.96 0.018 43.60%
Error 3 2.483 0.4966 18.22%
Total 6 13.62
5
100.00%
R-Sq. = 81.78%
Hav = 26.02 - 0.0239 I + 0.712 TS + 1.990 W.R
ƞ_(opt )= 26.02 - 0.0239 A1 + 0.712 B3 + 1.990 C3
A1= 160A B13=4 mm/sec C3=2.5 mm/min
Hav=30 mm
ANOVA for means of total height.

45. *

46. *
Source DOF Seq. SS Adj. MS F-value P-value Percent
contribution
I 1 1.08014 1.08014 12.07 0.018 34.15%
TS 1 0.07205 0.07205 0.80 0.411 2.28%
WR 1 1.56315 1.56315 17.46 0.009 49.42%
Error 5 0.44755 0.08951 14.15%
Total 8 3.16290 100.00%
R-Sq. = 85.85%
RMT = -3.32 + 0.01686 I - 0.110 TS + 1.021 W.R
ƞopt = −3.32 + 0.01686 𝐴1 − 0.110 𝐵2 + 1.021 𝐶1
A1=160 A B2= 3mm/sec C1= 1.5 mm/min
RMT=0.57 mm
ANOVA for means of Removed Metal Thickness.

47. *

48. *

49. *
Source DOF Seq. SS Adj. MS F-value P-value Percent
contributio
n
I 1 0.760 0.760 0.27 0.624 0.13%
TS 1 228.389 228.389 81.83 0.000 28.31%
WR 1 353.004 353.004 126.48 0.000 59.22%
Error 5 13.955 2.791 2.34%
Total 8 596.108 100.00%
R-Sq. = 97.66%
HV = 284.53 - 0.0141 I (A) + 6.170 TS (mm/sec) - 15.34 W.R
ƞopt = 284.53 − 0.0141 𝐴2 + 6.170 𝐵3 − 15.34 𝐶1
A2=190A B3=4 mm/sec C1=1.5 mm/min
HV=283.5
ANOVA for means of Hardness

50. *

51. *
250
255
260
265
270
275
280
1.5 2 2.5
Wire feed ratio
Microhardness/HV
0
0.5
1
1.5
2
2.5
1.5 2 2.5
Wire feed ratio
RemoveMetalThickness/mm

52. 0
5
10
15
20
25
30
No-W.R Low-W.R High-W.R
Hardness/HRC
Wire Feed Ratio W.R
0
5
10
15
20
25
30
35
40
No-W.R Low-W.R High-W.R
Hardness/HRC
Wire Feed Ratio W.R
(1) Effect of W.R on the hardness
(horizontal hardness readings).
(2) Effect of W.R on the hardness
(Vertical hardness readings).
Effect of W.R on Mechanical
Properties (Hardness)

53. (1) Effect of W.R on the Tensile Strength
(horizontal direction).
(2) Effect of W.R on the hardness
(Vertical direction).
Effect of W.R on Mechanical
Properties (Tensile test)
540
560
580
600
620
640
660
680
700
720
740
No-W.R Low-W.R High-W.R
TensileStrength/Mpa
Wire Feed Ratio W.R
460
470
480
490
500
510
520
530
540
550
No-W.R Low-W.R High-W.R
TensileStrength/Mpa
Wire Feed Ratio W.R

54. *
D
400X
W
V

55. *

56. *
0
100
200
300
400
500
600
700
800
900
1000
0 50 100 150 200 250
Temperature(C°)
Time ( per 10 sec))
T1 T2 T3 T4 To
Effect of W.R of temperature
distribution

57. *
0
100
200
300
400
500
600
700
800
900
1000
0 50 100 150 200 250 300 350
Temperature(C°)
Time ( per 10 sec)
T1 T2 T3 T4 To
Effect of W.R of temperature
distribution

58. 1. A new type of SMD system is designed and manufactured in the current work.
The results show that the machine has sufficient capacity to perform the work
during the tests. The ANSYS analysis show that the machine was performed on the
total deformation and stresses as well as the safety factor and the results showed
that the system is within the safe design. Also The ability of the system to draw the
complex paths of deposited parts
2. The used material fluxed-cored E309LTI-1 / T1-4 as self-protected filler metal in
the SMD process considers an economic process since it eliminates the cost of
using the protected gas.
Conclusions

59. 3. WR has a contribution 43% in maximizing total height and 49% in
minimizing the RMT and about 59 % in maximizing the hardness of
the deposited parts.
4. The optimal process parameters for maximum height are (i.e. I = 160 A, TS = 4
mm/sec, WR=2.5) is 30 mm, the optimum process parameters for minimum
removed metal thickness are A3B1C3 (i.e. welding current =160 A, travel speed =3
mm/sec, wire feed Ratio =1.5) is 0.5791 mm, and for maximum hardness are
A2B3C1 (i.e. welding current =190 A, travel speed =4 mm/sec, Wire Ratio=1.5
m/min) is 283.521.

60. 5. The external cold wire feed has a significant effect on the growth
of grains, where the increase of the cold feed reduces the roughness
of the grains and hence the microstructure of the grains seem as fine
and short dendritic.
6. Hardness reaching the vertical direction without cold feeding
about (25.56 HRC), while hardness with cold feeding reached
(34.82 HRC). Either in the horizontal direction hardness reached
(23.05 HRC) without cold feeding, while hardness reached (27.9
HRC) with cold feeding.

61. 7. UTS reaching the longitudinal direction without cold feeding about 608.63
Mpa, while the UTS with cold feeding reached 714.29 Mpa. Either in the vertical
direction UTS reached 492.46 without cold feeding, while the UTS reached
541.06 with cold feeding
8. The highest temperature obtained without cold feeding was 988
℃, while cold feeding was reduced to 900 ℃.
9. Cold feeding is an important addition to additive manufacturing
processes because of its significant impact on mechanical and
microscopic properties.

62. The final product of the CADWDM
system.