Process parameters investigation of a laser-generated single clad for minimum size using design of experiments

2013 ◽  
Vol 19 (6) ◽  
pp. 452-462 ◽  
Author(s):  
Mehmet Ermurat ◽  
Mehmet Ali Arslan ◽  
Fehmi Erzincanli ◽  
Ibrahim Uzman
Keyword(s):  
Design Of Experiments ◽  
Process Parameters ◽  
Flow Rate ◽  
Gas Flow ◽  
Optimum Parameter ◽  
Travel Speed ◽  
Standoff Distance ◽  
Gas Flow Rate ◽  
Focal Distance ◽  
Content Type

Purpose – This paper aims to investigate the effect of four important process parameters (i.e. laser focal distance, travel speed, feeding gas flow rate and standoff distance) on the size of single clad geometry created by coaxial nozzle-based powder deposition by high power laser. Design/methodology/approach – Design of experiments (DOE) and statistical analysis methods were both used to find optimum parameter combinations to get minimum sized clad, i.e. clad width and clad height. Factorial experiment arrays were used to design parameter combinations for creating experimental runs. Taguchi optimization methodology was used to find out optimum parameter levels to get minimum sized clad geometry. Response surface method was used to investigate the nonlinearity among parameters and variance analysis was used to assess the effectiveness level of each problem parameters. Findings – The overall results show that wisely selected four problem parameters have the most prominent effects on the final clad geometry. Generally, minimum clad size was achieved at higher levels of gas flow rate, travel speed and standoff distance and at minimum spot size level of the laser focal distance. Originality/value – This study presents considerable contributions in assessing the importance level of problems parameters on the optimum single clad geometry created laser-assisted direct metal part fabrication method. This procedure is somewhat complicated in understanding the effects of the selected problem parameters on the outcome. Therefore, DOE methodologies are utilized so that this operation can be better modeled/understood and automated for real life applications. The study also gives future direction for research based on the presented results.

scholarly journals The Effect of Process Parameters on the Microstructure and Mechanical Properties of AW5083 Aluminum Laser Weld Joints

Metals ◽  
2020 ◽  
Vol 10 (11) ◽  
pp. 1443 ◽  
Author(s):  
Maroš Vyskoč ◽  
Miroslav Sahul ◽  
Mária Dománková ◽  
Peter Jurči ◽  
Martin Sahul ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Process Parameters ◽  
Flow Rate ◽  
Weld Joint ◽  
Gas Flow ◽  
Filler Wire ◽  
Shielding Gas ◽  
Gas Flow Rate ◽  
Weld Joints

In this article, the effect of process parameters on the microstructure and mechanical properties of AW5083 aluminum alloy weld joints welded by a disk laser were studied. Butt welds were produced using 5087 (AlMg4.5MnZr) filler wire, with a diameter of 1.2 mm, and were protected from the ambient atmosphere by a mixture of argon and 30 vol.% of helium (Aluline He30). The widest weld joint (4.69 mm) and the highest tensile strength (309 MPa) were observed when a 30 L/min shielding gas flow rate was used. Conversely, the narrowest weld joint (4.15 mm) and the lowest tensile strength (160 MPa) were found when no shielding gas was used. The lowest average microhardness (55.4 HV0.1) was recorded when a 30 L/min shielding gas flow rate was used. The highest average microhardness (63.9 HV0.1) was observed when no shielding gas was used. In addition to the intermetallic compounds, β-Al3Mg2 and γ-Al12Mg17, in the inter-dendritic areas of the fusion zone (FZ), Al49Mg32, which has an irregular shape, was recorded. The application of the filler wire, which contains zirconium, resulted in grain refinement in the fusion zone. The protected weld joint was characterized by a ductile fracture in the base material (BM). A brittle fracture of the unshielded weld joint was caused by the presence of Al2O3 particles. The research results show that we achieved the optimal welding parameters, because no cracks and pores were present in the shielded weld metal (WM).

scholarly journals Application of Taguchi technique to optimize the gma welding parameters and study of fracture mode characterization of AISI 304H welded joints

2018 ◽  
Vol 9 (1) ◽  
pp. 9-16
Author(s):  
S. A. Rizvi
Keyword(s):  
Tensile Strength ◽  
Ultimate Tensile Strength ◽  
Process Parameters ◽  
Flow Rate ◽  
Fracture Mode ◽  
Welded Joints ◽  
Gas Flow ◽  
Welding Parameters ◽  
Taguchi Technique ◽  
Gas Flow Rate

This research article is focusing on the optimization of different welding process parameters which affect the weldability of stainless steel (AISI) 304H, Taguchi technique was used to optimize the welding parameters and the fracture mode characterization was studied. A number of experiments have been conducted. L9 orthogonal array (OA) (3×3) was applied. Analysis of variance ( ANOVA) and signal to noise ratio (SNR) was applied to determine the effect of different welding parameters such as welding current, wire feed speed and gas flow rate on mechanical, microstructure properties of SS304H. Ultimate tensile strength (UTS), toughness, microhardness (VHN), and mode of fracture was examined to determine weldability of AISI 304H and it was observed from results that welding voltage has major impact whereas gas flow rate has minor impact on ultimate tensile strength of the welded joints. Optimum process parameters were found to be 23 V, 350 IPM travel speed of wire and 15 l/min gas flow rate for tensile strength and mode of fracture was ductile fracture for tensile test specimen.

Uniform Ultra-Thin Oxides Grown by Rapid Thermal Oxidation of Silicon in N2O Ambient

1997 ◽  
Vol 470 ◽  
Author(s):  
G. C. Xing ◽  
D. Lopes ◽  
G. E. Miner
Keyword(s):  
Thermal Oxidation ◽  
Process Parameters ◽  
Flow Rate ◽  
Atmospheric Pressure ◽  
Gas Flow ◽  
Rotation Speed ◽  
Oxide Thickness ◽  
Gas Flow Rate ◽  
Rapid Thermal Oxidation ◽  
Nitrogen Concentrations

ABSTRACTIn this paper, we report the study of rapid thermal oxidation of silicon in N2O ambient using the Applied Materials RTP Centura rapid thermal processor, and N2O oxide thickness and compositional uniformities with respect to gas flow rate and wafer rotation speed as well as other process parameters. It was found that N2O oxide uniformity is strongly dependent on gas flow rate and wafer rotation speed in addition to process pressure. With optimized setting of the process parameters, excellent oxidation uniformities (one sigma < 1%) were obtained at atmospheric pressure N2O ambient. Nitrogen concentrations of such uniform oxides grown at 1050°C atmospheric pressure N2O oxidation processes were 1.7% for a 40Å oxide and 2.5% for a 60Å oxide, respectively, as characterized by SIMS analysis.

Metal Inert Gas (MIG) Welding Process Optimization for Joining Aluminum 5754 Sheet Material Using OTC/Daihen Equipment

Manufacturing ◽  
2003 ◽  
Author(s):  
R. Koganti ◽  
C. Karas ◽  
A. Joaquin ◽  
D. Henderson ◽  
M. Zaluzec ◽  
...  
Keyword(s):  
Aluminum Alloys ◽  
Process Parameters ◽  
Flow Rate ◽  
Gas Flow ◽  
Power Input ◽  
Interaction Effects ◽  
Inert Gas ◽  
Weld Penetration ◽  
Mig Welding ◽  
Gas Flow Rate

The development of lightweight vehicles, in particular aluminum intensive vehicles, require significant manufacturing process development for joining and assembling aluminum structures. Currently, 5xxx and 6xxx aluminum alloys are being used in various structural applications in a number of lightweight vehicles worldwide. Various joining methods, such as MIG, Laser and adhesive bonding have been investigated as technology enables for high volume joining of 5xxx, and 6xxx series alloys. In this study, metal inert gas (MIG) welding is used to join 5754 non-heat-treatable alloy sheet products. The objective of this study is to develop optimum weld process parameters for non-heat-treatable 5754 aluminum alloys. The MIG welding equipment used in this study is an OTC/Daihen CPD-350 welding systems and DR-4000 pulse power supply. The factors selected to understand the influence of weld process parameters on the mechanical properties and metallurgy (weld penetration) include power input (torch speed, voltage, current, wire feed), pulse frequency, and gas flow rate. Test coupons used in this study were based on a single lap configuration. A full factorial design of experiment (DOE) was conducted to understand the main and interaction effects on joint failure and weld penetration. The joint strengths and weld penetrations are measured for various operating ranges of weld factors. Post weld analysis indicates, power input and gas flow rate are the two signficant factors (statistically) based on lap shear load to failure and weld penentration data. There were no 2-way or 3-way interaction effects observed in ths weld study. Based on the joint strength and weld penetration, optimum weld process factors were determined.

Optimization of Process Parameters in Laser Welding of Hastelloy C-276 Using Artificial Neural Network and Genetic Algorithm

2020 ◽  
pp. 2050042
Author(s):  
K. R. SAMPREET ◽  
VASAREDDY MAHIDHAR ◽  
R. KARTHIC NARAYANAN ◽  
T. DEEPAN BHARATHI KANNAN
Keyword(s):  
Neural Network ◽  
Genetic Algorithm ◽  
Artificial Neural Network ◽  
Laser Welding ◽  
Process Parameters ◽  
Flow Rate ◽  
Gas Flow ◽  
Back Propagation ◽  
Gas Flow Rate ◽  
Bead Width

In this paper, an effort is made to determine the optimized parameters in laser welding of Hastelloy C-276 using Artificial Neural Network (ANN) and Genetic Algorithm (GA). CO2 Laser welding was performed on a sheet of thickness 1.6[Formula: see text]mm based on Taguchi L27 orthogonal array. Laser power, welding speed and shielding gas flow rate were chosen as input parameters and Bead width, depth of Penetration and Microhardness were measured for assessing the weld quality. ANN was applied for modeling the welding process parameters i.e. heat input, welding speed and gas flow rate. Various learning algorithms such as Batch Back Propagation (BBP), Incremental Back Propagation (IBP), Quick Propagation (QP) and Levenberg–Marquardt (LM) were comprehensively tested for estimating the output parameters and a comparison was also made among them, with respect to prediction accuracy. BBP method was found to be the best learning algorithm. Experimental validation test was performed based on the ANN and GA predicted optimized responses and this welding input parameters provided satisfactory weld metal characteristics in terms of penetration depth, bead width and microhardness.

A Taguchi Design Study for Optimisation of Plasma Sprayed Hydroxyapatite Coatings

2013 ◽  
Vol 773-774 ◽  
pp. 590-601
Author(s):  
Md Fahad Hasan ◽  
James Wang ◽  
Christopher C. Berndt
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Flow Rate ◽  
Feed Rate ◽  
Gas Flow ◽  
Deposition Efficiency ◽  
Gas Flow Rate ◽  
Powder Feed Rate ◽  
Hydroxyapatite Coatings ◽  
Plasma Sprayed

Plasma sprayed hydroxyapatite coatings were deposited onto mild steel substrates. A Taguchi L9design of experiment protocol was used to optimise the coating process parameters. The effect of three factors: (i) power and secondary gas flow rate (X1), (ii) powder feed rate and carrier gas flow rate (X2), and (iii) stand-off distance (X3) on the coating responses was studied. The responses of the plasma sprayed hydroxyapatite coatings were evaluated in terms of porosity, deposition efficiency, microhardness, crystallinity, and surface roughness. A regression analysis established relationships between process parameters and responses. Higher power, lower powder feed rate and the middle stand-off distance of 11 cm lead to optimum attributes of low porosity, high deposition efficiency, high microhardness, high crystallinity, and high surface roughness.

scholarly journals Enhancing corrosion resistance of A-TIG welded UNS S32750 joints by optimizing its technological parameters

2020 ◽  
Vol 26 (3) ◽  
pp. 249-257
Author(s):  
A. Arunmani ◽  
T. Senthilkumar
Keyword(s):  
Corrosion Resistance ◽  
Mass Loss ◽  
Process Parameters ◽  
Flow Rate ◽  
Welding Speed ◽  
Gas Flow ◽  
Welding Current ◽  
Inert Gas ◽  
Gas Flow Rate ◽  
Pitting Potential

In this paper, an attempt was made to improve the corrosion resistance of activated tungsten inert gas welded super duplex stainless steel such as UNS S 32750. Joints were fabricated by fluctuating the important process parameters such as welding speed, shielding gas flow rate and welding current, using NiO as activation flux. A central composited design model was developed for identification of the Activated Tungsten Inert Gas welding process parameter values for fabricating twenty joints. The welded joints were subjected to pitting corrosion test using an electrochemical corrosion testing system and salt spray testing was done for 48 h. Empirical relationships were developed for the process parameters with variations in the pitting potential and the rate of mass loss. The significance of the developed model was ascertained using analysis of variance method and optimization was done using response surface methodology. The joints fabricated at welding speed of 54.26 mm/min, welding current of 157 A and gas flow rate of 14.8 L/min, were found to have maximum pitting potential of -252.36 eV and minimum mass loss of 0.0108 g. Using validation experiments, the error was identified within three percentage which indicated that the optimization model was developed with very high predictability.

In Situ Functional Monitoring of Aerosol Jet-Printed Electronic Devices Using a Combined Sparse Representation-Based Classification (SRC) Approach

2018 ◽  
Author(s):  
Roozbeh (Ross) Salary ◽  
Jack P. Lombardi ◽  
Darshana L. Weerawarne ◽  
M. Samie Tootooni ◽  
Prahalada K. Rao ◽  
...  
Keyword(s):  
Sparse Representation ◽  
Functional Properties ◽  
Process Parameters ◽  
Flow Rate ◽  
Gas Flow ◽  
Electronic Devices ◽  
In Situ Monitoring ◽  
Gas Flow Rate ◽  
Aerosol Jet Printing

The goal of this work is in situ monitoring of the functional properties of aerosol jet-printed electronic devices. In pursuit of this goal, the objective is to develop a multiple-input, single-output (MISO) machine learning model to estimate the device functional properties in a near real-time fashion as a function of process parameters as well as 2D/3D features of line morphology. The aim is to use the MISO model for in situ estimation and thus, monitoring of line/device resistance in aerosol jet printing (AJP) process. To realize this objective, silver nanoparticle structures are printed by varying three process parameters: (i) sheath gas flow rate (ShGFR), (ii) exhaust gas flow rate (EGFR), and (iii) print speed (PS). Subsequently, line morphology is captured in situ using a high-resolution charge-coupled device (CCD) camera, mounted coaxial to the nozzle. Besides, utilizing 2D/3D quantifiers (introduced in the authors’ previous publications), the line morphology is further quantified, and the extracted features (e.g., line width, overspray, cross-sectional area, etc.) are fed as inputs to a novel sparse representation-based classification (SRC) model. The four-point probe method is used for measurement of resistance, and definition of a priori classification labels. The outcome of this research paves the way for future control of device functional properties in AJP process.

scholarly journals Prediction of Optimum Weld Tensile Strength Using Response Surface Methodology

2021 ◽  
Vol 6 (3) ◽  
pp. 81-84
Author(s):  
C. E. Etin-Osa ◽  
L. M. Ebhota
Keyword(s):  
Tensile Strength ◽  
Response Surface Methodology ◽  
Mild Steel ◽  
Tensile Test ◽  
Response Surface ◽  
Process Parameters ◽  
Flow Rate ◽  
Gas Flow ◽  
Experimental Result ◽  
Gas Flow Rate

Metals are often subjected to various types of stresses, usually under tensile stress, quick failure of material can be encouraged especially when poor combinations of process parameters are employed in joining of the material. Tensile strength is regarded as the maximum stress that a material can sustain under tension. The aim of this study is to predict the weld tensile strength of tungsten inert gas (TIG) mild steel welds using Response Surface Methodology (RSM), with the purpose of achieving optimum results. The input parameters considered were current, voltage, and gas flow rate. The TIG welding process was used to join two pieces of mild steel plates, after which tensile test was conducted on the specimen. The experimental result was analyzed using the RSM. Weld Tensile test of 596.218MPa with a desirability value of 95.70% was observed to be the best, resulting from the optimized process parameters of current of 120.00 Amp, voltage of 20.00 volt and gas flow rate of 12.00 L/min.

SCIENTIFIC AND ENGINEERING PRINCIPLES OF EFFICIENT FUEL USE AND ENVIRONMENTALLY FRIENDLY GAS COMBUSTION IN STOVE PLATES. PART 1. MODERN STATE-OF-THE-ART AND DIRECTIONS FOR IMPROVEMENT THE GAS BURNING IN DOMESTIC GAS COOKERS

2017 ◽  
pp. 3-18 ◽  
Author(s):  
B.S. Soroka ◽  
V.V. Horupa
Keyword(s):  
Natural Gas ◽  
Flow Rate ◽  
Gas Flow ◽  
Renewable Energy Sources ◽  
Combustion Process ◽  
Orifice Diameter ◽  
Firing Process ◽  
Gas Flow Rate ◽  
Gas Combustion ◽  
Gas Stoves

Natural gas NG consumption in industry and energy of Ukraine, in recent years falls down as a result of the crisis in the country’s economy, to a certain extent due to the introduction of renewable energy sources along with alternative technologies, while in the utility sector the consumption of fuel gas flow rate enhancing because of an increase the number of consumers. The natural gas is mostly using by domestic purpose for heating of premises and for cooking. These items of the gas utilization in Ukraine are already exceeding the NG consumption in industry. Cooking is proceeding directly in the living quarters, those usually do not meet the requirements of the Ukrainian norms DBN for the ventilation procedures. NG use in household gas stoves is of great importance from the standpoint of controlling the emissions of harmful components of combustion products along with maintenance the satisfactory energy efficiency characteristics of NG using. The main environment pollutants when burning the natural gas in gas stoves are including the nitrogen oxides NOx (to a greater extent — highly toxic NO2 component), carbon oxide CO, formaldehyde CH2O as well as hydrocarbons (unburned UHC and polyaromatic PAH). An overview of environmental documents to control CO and NOx emissions in comparison with the proper norms by USA, EU, Russian Federation, Australia and China, has been completed. The modern designs of the burners for gas stoves are considered along with defining the main characteristics: heat power, the natural gas flow rate, diameter of gas orifice, diameter and spacing the firing openings and other parameters. The modern physical and chemical principles of gas combustion by means of atmospheric ejection burners of gas cookers have been analyzed from the standpoints of combustion process stabilization and of ensuring the stability of flares. Among the factors of the firing process destabilization within the framework of analysis above mentioned, the following forms of unstable combustion/flame unstabilities have been considered: flashback, blow out or flame lifting, and the appearance of flame yellow tips. Bibl. 37, Fig. 11, Tab. 7.

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