DETERMINATION OF PROCESS PARAMETER FOR TWIN-WIRE WELD- DEPOSITION BASED ADDITIVE MANUFACTURING

ABSTRACT Various energy sources are available for sintering and/or depositing the material in additive manufacturing for metallic objects. These can be mainly categorized as laser based, electron beam based and arc based. While laser and electron offer better surface finish, it is possible to achieve high deposition rates in arc based weld-deposition. The inferior surface finish can be compensated by going for a hybrid system, combining deposition and machining. Twin-wire based weld-deposition, used in the present work, makes it possible to even realize functionally gradient material matrix; the use of two different filler materials into a single weld-pool makes this possible. Wire speed, torch speed and filler material are important factors that effect the composition of the deposited volume. Determination of the operating range and effect of these process parameters therefore is important to control the properties of the weld-deposited gradient objects. The current work presents the material composition of two filler materials ER70S6 and ER110SG with different wire speed and torch speed. Deposited material elemental compositions were analyzed using ED-XRF machine

Thermo-Mechanical Modelling of Arc Welding

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Twin-wire welding based additive manufacturing (TWAM): manufacture of functionally gradient objects

For dissimilar twin-wire weld-deposition used here, it is observed that the resultant hardness is in the volumetric proportion of the hardness of the individual filler wires. This aids the fabrication of FGMs using arc based weld-deposition with localized control of hardness, achieved through the control of the ratio of wire speeds of the individual filler wires. Four sample parts were fabricated to demonstrate the concept of realizing FGMs through TWAM. The fabricated parts showed good match with the desired hardness variation