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Additive manufacturing (AM) is seeing a significant surge in various industries these days. Wire arc additive manufacturing (WAAM) is well-known for impressive speed of material deposition and the capability to create high-quality products of any size. This research explores the application of PICO-MIG welding through Inconel 82 in the WAAM process. Pico-MIG welding is a specialised form of MIG welding for the purpose of constructing large-scale components, PICO- MIG welding offers a superior level of productivity compared to traditional MIG welding, allowing for a high deposition rate. The study investigates the effects of heat input on WAAM characteristics, highlighting the importance of layering techniques. A 6-layered wall is built using carefully calculated parameters obtained from experimental trials. Through conducting scratch tests, hardness values (HSp) were determined to be 0.00491 GPa, 0.004836 GPa, & 0.00421 GPa for loads of 45N, 55N, & 65N, respectively. After conducting Scanning Electron Microscope (SEM), the analysis reveals the surface topography analysis, dendritic structures, and the presence of combined grain particle. X-ray Diffraction (XRD) can provide valuable insights into the chemical composition and presence of secondary phases. The hardness tests reveal a wide range of values, with the highest being 323.5 HV and the lowest being 107 HV. These measurements were obtained using loads of 1 kg and 0.1 kg. Interestingly, there was one exceptional case where the hardness reached 314 HV at a load of 0.2 kg.

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Optimization of Wire Arc Additive Manufacturing Through Analysis of Process Parameters and Their Influence on Microstructure Evolution

  • 会议论文

  • 发表日期：

    2025年

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  • N. Chethan Kumar,
  • Suyog Jhavar,
  • S. Sandeep Kumar,
  • K. V. Harsha Sathvik,
  • A. Durga Ganesh Ratna Kumar,
  • Aritra Saha

摘要

Additive manufacturing (AM) is seeing a significant surge in various industries these days. Wire arc additive manufacturing (WAAM) is well-known for impressive speed of material deposition and the capability to create high-quality products of any size. This research explores the application of PICO-MIG welding through Inconel 82 in the WAAM process. Pico-MIG welding is a specialised form of MIG welding for the purpose of constructing large-scale components, PICO- MIG welding offers a superior level of productivity compared to traditional MIG welding, allowing for a high deposition rate. The study investigates the effects of heat input on WAAM characteristics, highlighting the importance of layering techniques. A 6-layered wall is built using carefully calculated parameters obtained from experimental trials. Through conducting scratch tests, hardness values (HSp) were determined to be 0.00491 GPa, 0.004836 GPa, & 0.00421 GPa for loads of 45N, 55N, & 65N, respectively. After conducting Scanning Electron Microscope (SEM), the analysis reveals the surface topography analysis, dendritic structures, and the presence of combined grain particle. X-ray Diffraction (XRD) can provide valuable insights into the chemical composition and presence of secondary phases. The hardness tests reveal a wide range of values, with the highest being 323.5 HV and the lowest being 107 HV. These measurements were obtained using loads of 1 kg and 0.1 kg. Interestingly, there was one exceptional case where the hardness reached 314 HV at a load of 0.2 kg.