Comparison of Mechanical Properties of Ni-Al-Bronze Alloy Fabricated through Wire Arc Additive Manufacturing with Ni-Al-Bronze Alloy Fabricated through Casting
Abstract
:1. Introduction
2. Experiment Method
2.1. Experiment Preparation
2.2. Substrate and Deposition Material
2.3. Deposition Parameters of the WAAM Process
2.4. Material Assessment
3. Results and Discussion
3.1. Effect of Wire Feed Rate for Single Bead
3.2. Tensile Strength Results
3.3. Hardness
3.4. Impact Test Results
3.5. Wear Test Results
4. Conclusions
- The study analyzed the shape of an NAB single bead using the CMT process and found that the wire feed rate per heat input needs a minimum heat input of 0.54 kJ·s/cm2, and that the contact angle becomes closer to 90° when the wire feed rate is about 7 m/min. A contact angle close to 90° is required to make a single bead shape suitable for the deposition process.
- Regarding the tensile strength results, the deposited NAB showed 50% higher tensile strength, 20% higher average yield strength, and 60% higher average elongation compared to the cast NAB (substrate). The NAB material fabricated by WAAM has anisotropy, and the stress results differed depending on the tensile direction of laminated part. The average tensile strength was 718 MPa, the average yield strength was 391 MPa, and the average elongation was 25.1% for type 1 (transverse direction). For type 2 (transverse direction), the average tensile strength was 735 MPa, the average yield strength was 425 MPa, and the average elongation was 27.7%.
- Regarding the Vickers hardness measurement results, type 2 (longitudinal) showed higher hardness, which is similar to the tensile strength test results. The average hardness of type 1 (transverse) was 196.8 HV, and the average hardness of type 2 (longitudinal) was 218.4 HV. The average hardness of the casting material (substrate) was 170.8 HV. The hardness of type 2 (longitudinal) was improved by 10% compared to type 1 (transverse), and by about 28% compared to the casting material (substrate).
- Regarding the wear test results, the abrasion resistance of the deposited NAB material showed better performance than that of the casting material (substrate) in terms of indentation depth and weight loss. In addition, the friction coefficient of the deposited NAB was smaller than that of the casting material (substrate), so there is less part damage caused by friction.
Author Contributions
Funding
Conflicts of Interest
References
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Cu | Al | Ni | Fe | Mn | Si | Zn | Sn | Pb | |
---|---|---|---|---|---|---|---|---|---|
Substrate (C63000) | Bal. | 9.11 | 4.28 | 3.3 | 0.9 | 0.01 | 0.02 | 0.01 | 0.04 |
Wire (ERCuNiAl) | Bal. | 8.8 | 5.2 | 3.3 | 0.8 | 0.002 | 0.003 | 0.002 | 0.002 |
Weld ID. No. | Current (A) | Voltage (V) | Travel Speed (cm/min) | Wire Feed Rate (m/min) | Heat Input (kJ) | Wire Feed Rate Per Heat Input Rate (kJ·s/cm2) | |
---|---|---|---|---|---|---|---|
1 | 118 | 11.5 | 30 | 5 | 2.714 | 0.54 | |
2 | 147 | 11.8 | 30 | 6 | 3.4692 | 0.57 | |
3 | 163 | 11.7 | 30 | 7 | 3.8142 | 0.54 | |
4 | 184 | 11.8 | 30 | 8 | 4.3424 | 0.54 | |
5 | 197 | 12.9 | 30 | 9 | 5.0826 | 0.56 | |
6 | 214 | 14.4 | 30 | 10 | 6.1632 | 0.61 | |
Fixed Parameters for GMAW (gas metal arc welding) process | |||||||
CTWD (contact tip to walk distance) (mm) | Shielding gas (L/min) | ||||||
15 | 15 |
Process Parameter | Type 1 | Type 2 | Type 3 (for Wear Test) |
---|---|---|---|
Current (A) | 163~165 | ||
Voltage (V) | 11.8~12.0 | ||
Travel Speed (cm/min) | 30 | ||
CTWD (mm) | 15~15.5 | ||
Wire Feed Rate (m/min) | 7 | ||
Shielding Gas (l/min) | 15 (Ar 100%) | ||
Overlap Pitch (mm) | 4~4.5 | ||
Deposition Bulk Size | 150 mm (L) × 60 mm (W) × 25 nm (H) | 60 mm (D) × 25 nm (H) | |
Deposition Path Type |
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Kim, J.; Kim, J.; Pyo, C. Comparison of Mechanical Properties of Ni-Al-Bronze Alloy Fabricated through Wire Arc Additive Manufacturing with Ni-Al-Bronze Alloy Fabricated through Casting. Metals 2020, 10, 1164. https://doi.org/10.3390/met10091164
Kim J, Kim J, Pyo C. Comparison of Mechanical Properties of Ni-Al-Bronze Alloy Fabricated through Wire Arc Additive Manufacturing with Ni-Al-Bronze Alloy Fabricated through Casting. Metals. 2020; 10(9):1164. https://doi.org/10.3390/met10091164
Chicago/Turabian StyleKim, Jisun, Jaewoong Kim, and Changmin Pyo. 2020. "Comparison of Mechanical Properties of Ni-Al-Bronze Alloy Fabricated through Wire Arc Additive Manufacturing with Ni-Al-Bronze Alloy Fabricated through Casting" Metals 10, no. 9: 1164. https://doi.org/10.3390/met10091164