09.2021.226.236

Effects Of Wire Feeding Angle in Wire Arc Additive Manufacturing

Author(s):

Nor Ana Rosli, Mohd Rizal Alkahari†,‡,*, Mohd Fadzli bin Abdollah†,††, Shajahan Maidin‡‡, Faiz Redza Ramli†,††, Safarudin Gazali Herawan†††

Affiliation(s):

Fakulti Kejuruteraan Mekanikal, Universiti Teknikal Malaysia Melaka, Hang Tuah Jaya, 76100 Durian Tunggal, Melaka, Malaysia

Advanced Manufacturing Center, Universiti Teknikal Malaysia Melaka, Hang Tuah Jaya, 76100 Durian Tunggal, Melaka, Malaysia

††Center for Advanced Research on Energy, Universiti Teknikal Malaysia Melaka, Hang Tuah Jaya, 76100 Durian Tunggal, Melaka, Malaysia

‡‡Fakulti Kejuruteraan Pembuatan, Universiti Teknikal Malaysia Melaka, Hang Tuah Jaya, 76100 Durian Tunggal, Melaka, Malaysia

†††Industrial Engineering Department, Fakulti Kejuruteraan, Universitas Bina Nusantara, Jakarta, 11430 Indonesia

Corresponding Author Email: rizalalkahari@utem.edu.my

This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

Wire arc additive manufacturing (WAAM) is an additive manufacturing (AM) or 3D printing technique that may employs welding arc to melt the metal wire for production metal parts. WAAM offers an advantage of reducing waste material, referred to as the buy to fly ratio and lead manufacturing time. As the application of micro plasma arc welding is rarely being used in the WAAM process, this study aims to find a suitable range of process parameter for a stable and continuous single weld bead deposition of micro plasma based WAAM. During 3D printing, the consistent and predictable single bead formation is essential in ensuring good quality of the printed structure. Hence, relationship among the different process parameters need to be well-established with proper determination of optimum welding parameters since it is corresponding to the final desired bead geometry. In this study, influence of process parameters on the built object geometry under several process conditions during WAAM was studied. This study primarily focusing on wire feeding angle of 30º and 60º at combination of various speed with the goal of obtaining continuous layer and reducing the difference in the layer height. The result indicates at wire feed angle of 30º, inconsistent deposition is produced. As the wire feed angle was set to 60º, a more uniform deposition is obtained. It is also found that, the hardness of deposited single layer decreases gradually from the substrate to the top zone of the 3D printed structure.