ENHANCING DEPOSITION QUALITY OF ALUMINUM ALLOY 5356 THROUGH OPTIMIZATION OF WAAM PROCESS PARAMETERS
- Authors
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C. C. Chiabuotu
Mechanical Engineering Department, Federal University of Technology Owerri, PMB. 1526, Owerri. Imo State, Nigeria
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T. E. Abioye
Industrial Production Engineering Department, Federal University of Technology, Akure. Ondo State, Nigeria
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O. M. Olabanji
Mechanical Engineering Department, Federal University of Technology, Akure. Ondo State, Nigeria.
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- Keywords:
- wire arc additive manufacturing (WAAM), aluminum 5356, process optimization, track geometry, analysis of variance, multi-track deposition
- Abstract
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Wire Arc Additive Manufacturing (WAAM) gives a transformative method for fabricating components from 5356 aluminum alloy, a material which is a sought after because of its good mechanical properties and its common use in aerospace sector. WAAM technique has many advantages but parts produce through the process faces such problems as porosity, cracking, and warping. These limitations can affect the structural integrity of the produced parts and manufacturing efficiency is reduced since post-processing activities are required. This study aims at optimizing WAAM process parameters so that the geometry and quality of single-track deposits of AA5356 can be improved. The study made use of a full factorial experimental design that involves three factors at three levels to explore the process window. This was done to identify the optimal combination of parameters, which yield high dimensional accuracy and surface integrity devoid of pores, cracks and other defects. It was found out that the height of the track increased as the wire feed rate increased and the traverse speed decreased. The optimal deposition parameters that will yield material with both high dimensional accuracy and structural integrity were found out and were used for the deposition of well-defined single tracks with aspect ratios between 1.5 and 4, acute contact angles, and minimal porosity. These conditions helped to achieve a defect-free tracks with excellent dimensional consistency. These findings advertises the use of WAAM technology in the manufacturing industries as well as makes available a solid foundation for subsequent research and industrial implementation.
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