Influence of p-MIG Welding Parameters to Wall Geometry of Aluminium Alloy 2319 Fabricated Using WAAM

Abstract

Arc welding processes are used in additive manufacturing today, adding thin layers of metal according to a programmed heat source path. This paper presents a study of the influence of robotic p-MIG process parameters on wall geometry made of aluminium alloy 2319. Experimental methodology was based on variation of arc travel speed (6, 7, 8 mm/s), with constant heat input per layer length and suitable arc power. The selected heat input per layer length for the first layer was 265 J/mm ± 5%, and for the other layers it was 217 J/mm ± 5%. The analysis of wall geometry, layer height and width, considering deposition efficiency and surface waviness index, was applied in the research. The results showed that same heat input with different WAAM process parameters yielded different wall geometries and wall geometry quality. 3D model of the wall geometry proved to be a useful tool for volume and deposition efficiency calculations. Moreover, the graphical display and interpretation of the standard deviation shows the level of stability of the geometric features of the wall layers. Based on the implemented methodology, an appropriate selection of process parameters is given to achieve the most efficient wall geometry of aluminium alloy 2319.

Keywords

• aluminium alloy 2319
• deposition efficiency
• heat input
• p-MIG welding parameters
• wall geometry
• wire arc additive manufacturing