scholarly journals Using multiple performance characteristics to optimize the percent zinc coating balances edge joints of galvanized steel sheets for metal inert gas pulse brazing process

2017 ◽  
Vol 9 (7) ◽  
pp. 168781401771498
Author(s):  
Khasempong Songsorn ◽  
Keartisak Sriprateep ◽  
Sampan Rittidech
Keyword(s):  
Zinc Coating ◽  
Travel Speed ◽  
Pulse Frequency ◽  
Performance Characteristics ◽  
Galvanized Steel ◽  
Inert Gas ◽  
Feed Speed ◽  
Steel Sheets ◽  
Wire Feed Speed ◽  
Percent Zinc

In this article, an optimization technique using the Taguchi method with multiple performance characteristics for the percent zinc coating balances edge joints of galvanized steel sheets for metal inert gas pulse brazing process was proposed. The orthogonal array, multi-response signal-to-noise ratio, and analysis of variance were employed to study the performance characteristics. Five metal inert gas pulse brazing process parameters, namely, wire feed speed, arc voltages, travel speed, peak currents, and pulse frequency, were optimized with considerations of multiple performance characteristics including percent zinc coating balances edge joints. Experimental results were provided to confirm the effectiveness of this approach. The optimum metal inert gas pulse brazing technique conditions were wire feed speed of 3.25 m/min, arc voltages of 18 V, travel speed of 0.8 m/min, peak currents of 425 A, and pulse frequency of 35 Hz. Confirmation tests of the optimal levels with the initial cutting parameters are carried out in order to illustrate the effectiveness of this method in metal inert gas pulse brazing technique for galvanized steel sheets.

scholarly journals Balancing WAAM Production Costs and Wall Surface Quality through Parameter Selection: A Case Study of an Al-Mg5 Alloy Multilayer-Non-Oscillated Single Pass Wall

2019 ◽  
Vol 3 (2) ◽  
pp. 32 ◽  
Author(s):  
Yuri Yehorov ◽  
Leandro João da Silva ◽  
Américo Scotti
Keyword(s):  
Deposition Time ◽  
Travel Speed ◽  
Production Costs ◽  
Constant Current ◽  
Feed Speed ◽  
Surface Waviness ◽  
Single Pass ◽  
Target Wall ◽  
Wire Feed Speed ◽  
Wire Feed

The purpose of the study was to propose a strategy to assess the potential reduction of the production cost during wire+arc additive manufacturing (WAAM) based on the combination of wire feed speed (related to deposition rate) and travel speed (related to deposition time). A series of experiments, using a multilayer-non-oscillated single pass wall made of an Al-Mg alloy, was conducted. The quality of the wall was assessed through the lateral surface waviness and top layer undulation. The concepts of Surface Waviness and Buy-to-Apply indices were introduced. Initially, the range of travel speed (TS) that provided layers with acceptable quality was determined for a given wire feed speed (WFS), corresponding to a constant current. Then, the effect of the increase of production capacity of the process (though current raising, yet maintaining the ratio WFS/TS constant) on the wall quality for a given condition within the TS range was assessed. The results showed that the useful range of TS prevents too rough a waving surface below the lower limit and top surface undulation over the higher limit. However, inside the range, there is little quality variation for the case under study. Finally, simulations of deposition time were developed to demonstrate the weight of the TS on the final deposition time and wall quality as a function of a target wall width. This respective weight showed the existence of a complex and unpredictable, yet determined, power of a combination of TS, target wall geometry, and dead time between subsequent layers. It was verified to be possible to find optimized TS as a function of different target geometries.

Weldability and Distortion of Mg AZ31-to-Galvanized Steel SPOT Plug Welding Joint by Cold Metal Transfer Method

2016 ◽  
Vol 139 (2) ◽  
Author(s):  
R. Cao ◽  
Q. W. Xu ◽  
H. X. Zhu ◽  
G. J. Mao ◽  
Q. Lin ◽  
...  
Keyword(s):  
Mild Steel ◽  
Weld Metal ◽  
Base Metal ◽  
Metal Transfer ◽  
Galvanized Steel ◽  
Feed Speed ◽  
Process Variables ◽  
Cold Metal Transfer ◽  
Wire Feed Speed ◽  
Cold Metal

In this study, cold metal transfer (CMT) plug welding of 1 mm thick Mg AZ31 to 1 mm thick hot-dipped galvanized mild steel (i.e., Q235) was studied. Welding tests were performed and the process variables optimized with Mg AZ61 wire and 100% argon shielding gas for a plug weld located in the center of the 25 mm overlap region. It was found that it is feasible to join 1 mm thick Mg AZ31 workpiece to 1 mm thick galvanized mild steel using CMT plug welding. The optimized process variables for CMT plug welding Mg AZ31-to-galvanized mild steel were a wire feed speed of 10.5 m/min, a predrilled hole with a diameter of 8 mm in Mg AZ31 workpiece and a welding time of 0.8 s. CMT plug welded Mg AZ31-to-galvanized mild steel joints were composed of the fusion zone between Mg AZ31 base metal and Mg weld metal, Mg weld metal (i.e., combined base metal, filler wire and Zn coating), and the brazing interface between magnesium weld metal and galvanized mild steel. The brazing interface mainly consisted of Al, Zn, Mg, Si intermetallic compounds and oxides (i.e., Fe3Al, Mg2Si, MgZn, and MgZn2), and magnesium solid solution. The static strength of CMT welded-brazed Mg AZ31-galvanized steel was determined primarily by the strength and area of the brazed interface and thickness of the intermetallic reaction layer.

Process Development for a Robotized Laser Wire Additive Manufacturing

2017 ◽  
Author(s):  
Meysam Akbari ◽  
Yaoyu Ding ◽  
Radovan Kovacevic
Keyword(s):  
Additive Manufacturing ◽  
Process Parameters ◽  
Process Development ◽  
Laser Scanner ◽  
Travel Speed ◽  
Main Process ◽  
Feed Speed ◽  
Wire Feed Speed ◽  
Deposition Processes ◽  
Complicated Geometries

Additive manufacturing has attracted the attention of industries such as aerospace and automotive as well as the medical technology sectors in recent years. Among all metal-based additive techniques, laser metal wire deposition offers some advantages like shorter processing time, more efficient material usage, and a larger buildup envelop. It has been found that robotized laser/wire additive manufacturing (RLWAM) is a demanding process. A plethora of process parameters must be controlled compared to other laser-based metal deposition processes. The influence of main process parameters such as laser power, stepover increment, wire feed speed, travel speed and z-increment was investigated in this study to find the optimal values. Droplet formation, wire dripping, irregular deposition in the first layer, and deviation of the wire tip were also found to be the main obstacles throughout the process and practical solutions were proposed to deal with these issues. In this study, an 8-axis robot (6-axis arm robot with a 2-axis positioner) and a 4 kW fiber laser along with a wire feeder were integrated to print the different geometrical shapes in 3D. In order to verify the geometrical accuracy of the as-built part, the buildup was scanned using a portable 3D laser scanner. The 3D representation, the Standard Tessellation Language (STL) format obtained from the buildup, was compared with the original CAD model. The results show that RLWAM can be successfully applied in printing even complicated geometries.

Formation and improvement of surface waviness for additive manufacturing 5A06 aluminium alloy component with GTAW system

2018 ◽  
Vol 24 (2) ◽  
pp. 342-350 ◽  
Author(s):  
Haibin Geng ◽  
Jinglong Li ◽  
Jiangtao Xiong ◽  
Xin Lin ◽  
Dan Huang ◽  
...  
Keyword(s):  
Travel Speed ◽  
Feed Speed ◽  
Surface Waviness ◽  
Forming Process ◽  
Line Energy ◽  
Content Type ◽  
Wire Feed Speed ◽  
The Given ◽  
Wire Feed ◽  
Matching Relation

Purpose As known, the wire and arc additive manufacture technique can achieve stable process control, which is represented with periodic surface waviness, when using empirical methods or feedback control system. But it is usually a tedious work to further reduce it using trial and error method. The purpose of this paper is to unveil the formation mechanism of surface waviness and develop a method to diminish it. Design/methodology/approach Two forming mechanisms, wetting and spreading and remelting, are unveiled by cross-section observation. A discriminant is established to differentiate which mechanism is valid to dominate the forming process under the given process parameters. Findings Finally, a theoretical method is developed to optimize surface waviness, even forming a smooth surface by establishing a matching relation between heat input (line energy) and materials input (the ratio of wire feed speed to travel speed). Originality/value Formation mechanisms are revealed by observing cross-section morphology. A discriminant is established to differentiate which mechanism is valid to dominate the forming process under the given process parameters. A mathematical model is developed to optimize surface waviness, even forming a smooth surface through establishing a matching relation between heat input (line energy) and materials input (the ratio of wire feed speed to travel speed).

scholarly journals Study of Arc-wire and Laser-wire processes for the realization of Ti-6Al-4V alloy parts

2020 ◽  
Vol 321 ◽  
pp. 03002
Author(s):  
A. Ayed ◽  
G. Bras ◽  
H. Bernard ◽  
P. Michaud ◽  
Y. Balcaen ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Travel Speed ◽  
Feed Speed ◽  
Laser Additive Manufacturing ◽  
Powder Bed ◽  
Wire Feed Speed ◽  
Manufacturing Techniques ◽  
Parameter Ranges ◽  
Wire Arc Additive Manufacturing ◽  
Wire Feed

Arc-wire or laser-wire additive manufacturing seems promising because it allows large parts to be produced with significant deposition rates (ten times higher than powder bed additive manufacturing), for a lower investment cost. These additive manufacturing techniques are also very interesting for the construction or the repair of parts. A versatile 3D printing device using a Wire Arc Additive Manufacturing (WAAM) station or laser device Wire Laser Additive Manufacturing (WLAM) for melting a filler wire is developed to repair and build large titanium parts. The final objectives of the study are to optimize the process parameters to control the dimensional stability, the metallurgical and mechanical properties of the produced parts. In this paper, an experimental study is carried out to determine the first order process parameter ranges (synergic law, laser power, wire feed speed, travel speed) appropriate for these two techniques, for repair or construction parts on Ti-6 Al-4V.

Interface Microstructure and Adhesion of Zinc Coatings on TRIP Steels

2007 ◽  
Vol 539-543 ◽  
pp. 1104-1109 ◽  
Author(s):  
G.M. Song ◽  
Willem G. Sloof ◽  
T. Vystavel ◽  
Jeff T.M. de Hosson
Keyword(s):  
Trip Steel ◽  
Tensile Deformation ◽  
Steel Substrate ◽  
Zinc Coating ◽  
Galvanized Steel ◽  
Interface Fracture ◽  
Inhibition Layer ◽  
Steel Sheets ◽  
Intermetallic Particles ◽  
Zinc Coatings

Hot-dip galvanized transformation induced plasticity (TRIP) steel sheets were recently developed for automotive applications. The microstructure and the adhesion of zinc coated CMnSi TRIP steel alloyed with P were studied. The α-Zn coating adjacent to the steel substrate consists of a continuous η-Fe2Al5-xZnx inhibition layer with columnar ζ-FeZn13 intermetallic particles on top. Along the interface between the inhibition layer and the steel substrate Mn/Mn-P oxides were frequently observed. Although these oxides at the steel surface reduce the adhesion between the zinc coating and the TRIP steel, they do not cause any bare spots during galvanizing. Upon tensile deformation of the galvanized steel sheet, cracking along the α-zinc grain boundaries preceded fracture of the interface between the α-Zn layer and the inhibition layer. After 4 % deformation the average interface crack length increased linearly with the applied strain. This interface fracture was strongly influenced by the crystalline orientation of the α-Zn grains.

Evaluation of Corrosion Resistance of Galvanized Steel Sheets Used in Automotive Production

2015 ◽  
Vol 818 ◽  
pp. 141-144
Author(s):  
Luboš Kaščák ◽  
Janette Brezinová ◽  
Jacek Mucha
Keyword(s):  
Corrosion Resistance ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Zinc Coating ◽  
High Rate ◽  
Galvanized Steel ◽  
Electrochemical Characteristics ◽  
Resistance Spot ◽  
Steel Sheets ◽  
Body Production

The steel sheets used for the car body production are protected against corrosion by zinc coating. Resistance spot welding is used mainly for joining these sheets, because of its high speed and adaptability for automation in high-rate production. However, resistance spot welding has a negative influence on the corrosion resistance of joints. The paper focuses on the analysis of quality of welds on galvanized steel sheets and their corrosive properties. Tensile test and accelerated corrosion test in corrosive environment were used for evaluation of the welds’ quality. Protective efficiency of zinc coatings for automobile sheets was evaluated as well, based on the determination of their electrochemical characteristics in passivated and non-passivated state, as well as their corrosion resistance in simulated corrosion environments. Two types of DX54D+Z material were used for experiments: non-passivated and passivated with Cr3+.

scholarly journals Transferability of the working envelope approach for parameter selection and optimization in thin wall WAAM

2021 ◽  
Author(s):  
Felipe Ribeiro Teixeira ◽  
Fernando Matos Scotti ◽  
Louriel Oliveira Vilarinho ◽  
Carlos Alberto Mendes da Mota ◽  
Américo Scotti
Keyword(s):  
Surface Finish ◽  
Steel Wire ◽  
Travel Speed ◽  
Parameter Selection ◽  
Basic Material ◽  
Feed Speed ◽  
Thin Wall ◽  
Wall Width ◽  
Thin Walls ◽  
Wire Feed Speed

AbstractThis work aims to propose and assess a methodology for parameterization for WAAM of thin walls based on a previously existing working envelope built for a basic material (parameter transferability). This work also aimed at investigating whether the working envelope approach can be used to optimize the parameterization for a target wall width in terms of arc energy (which governs microstructure and microhardness), surface finish and active deposition time. To reach the main objective, first, a reference working envelope was developed through a series of deposited walls with a plain C-Mn steel wire. Wire feed speed (WFS) and travel speed (TS) were treated as independent variables, while the geometric wall features were considered dependent variables. After validation, three combinations of WFS and TS capable of achieving the same effective wall width were deposited with a 2.25Cr-1Mo steel wire. To evaluate the parameter transferability between the two materials, the geometric features of these walls were measured and compared with the predicted values. The results showed minor deviations between the predicted and measured values. As a result, WAAM parameter selection for another material showed to be feasible after only fewer experiments (shorter time and lower resource consumption) from a working envelope previously developed. The usage of the approach to optimize parameterization was also demonstrated. For this case, lower values of WFS and TS were capable of achieving a better surface finish. However, higher WFS and TS are advantageous in terms of production time. As long as the same wall width is maintained, variations in WFS and TS do not significantly affect microstructure and microhardness.

Sign in / Sign up

Export Citation Format

Share Document