INVESTIGATION ON MECHANICAL PROPERTIES OF WIRE

ARC ADDITIVE MANUFACTURING (WAAM) OF STAINLESS

STEEL USING FEM SIMULATION AND EXPERIMENT

MOHAMAD AIMAN BIN YAZID

(2015475448)

BACHELOR OF MECHANICAL ENGINEERING

UNIVERSITI TEKNOLOGI MARA
“I declare that this thesis is the result of my own work except the ideas and summaries
which I have clarified their sources. The thesis has not been accepted for any degree
and is not concurrently submitted in candidature of any degree”

Signed: …………………………

Date: ………………..

MOHD AIMAN BIN YAZID

UiTM No.: 2015475448

“I declare that I read this thesis and in my point of view this thesis is qualified in terms
of scope and quality for the purpose of awarding the Bachelor of Engineering
(Honours) Mechanical”

Signed:…………………………

Date:……………………

Supervisor
Prof. Dr. Ing. Yupiter Hp Manurung
Faculty of Mechanical Engineering
Universiti Teknologi MARA (UiTM)
40450 Shah Alam Selangor

Signed:…………………………

Date:……………………

Co-Supervisor
En. Muhd Faiz bin Mat
Faculty of Mechanical Engineering
Universiti Teknologi MARA (UiTM)
40450 Shah Alam Selangor
 INVESTIGATION ON MECHANICAL PROPERTIES OF WIRE ARC
ADDITIVE MANUFACTURING (WAAM) OF STAINLESS STEEL USING
FEM SIMULATION AND EXPERIMENT

MOHAMAD AIMAN BIN YAZID

(2015475448)

A thesis submitted in partial fulfilment of the requirements for the award of Bachelor of
Engineering (Honours) Mechanical

Faculty of Mechanical Engineering

Universiti Teknologi MARA (UiTM)

JULY 2019
 ACKNOWLEDGEMENTS

I've worked hard on this project. But without the kind support and help of many
individuals and organizations, it would not have been possible. I would like to extend to
all of them my sincere thanks. Foremost, I want offer this endover to our GOD
Almighty for the wisdom he bestowed upon me, the strength, peace of my mind and
good heath in order to finish this research. I am deeply grateful for the guidance and
ongoing oversight of my Supervisor, Prof. Yupitar HP Manurung, who has the attitude
and the substance of a genius with continually and convincingly conveyed a spirit of an
adventure in regard to my research. Then, also to my Co-Supervisor, En Faiz bin Mat
for the needed information on the project as well as his support for the final year
project. I would also like to express my appreciation to my parents and technician at the
Faculty of Mechanical Engineering for their kind cooperation and encouragement in
assisting me to complete this project. I am also grateful to my friends and the people
who have helped me to develop the project with their skills and knowledge.

ii
 ABSTRCT

Wire Arc Additive Manufacturing (WAAM) process forms a part with complex
geometry over the layer-by-layer deposition of welded beads, it is important to model
the geometry of a single weld bead as well as the multi-bead overlap process to achieve
high surface quality and dimensional accuracy of manufactured parts. This study
produces 316L stainless steel parts through experimental set-up and FEM simulation.
WAAM is used to fabricate the part of ten layers with three string of 316L stainless
steel. The ABB IRB 2400/16 is the robotic welding used for this experimental process
equipped with GMAW power source KEMMPI Pro Evolution Pro-MIG 540MXE. The
FEM Simulation will focus on the comparison of all temperature strain hardening
model to high temperature for stainless steel 316L material. The specimen will be term
of welding quality on the profile, material composition and simulated by using FEM
simulation. On simulation, the best parameters that perform as the manipulated
variables that are welding speed, the current used for welding, the wire feed rate and the
cooling time required for each layer that are responsible for the quality and changes in
the microstructure characteristics of the WAAM products. The specimen was prepared
to find the quality of the welding by Vickers Hardness test. Macrostructure also
required to calibrate size of every weld filler between simulation and experimental. The
chemical composition of the wire and the specimen was identifying for ensure both are
match by using the Energy Dispersive X-Ray Analysis (EDX) machine. The residual
stress of the WAAM also discover by using X-Ray Diffraction (XRD) for comparison
experimental and FEM simulation using MSC Marc Mentat software. All values were
analyzing and discussed the new development of 316L Stainless steel on Wire Arc
Additive Manufacturing (WAAM).

iii
 TABLE OF CONTENT

DECLARATION

TITLE PAGE

ACKNOWLEDGEMENTS ii

ABSTRACT Error! Bookmark not defined.

TABLE OF CONTENT ⅳ

LIST OF TABLES ⅵ

LIST OF FIGURES ⅶ

LIST OF SYMBOLS ⅹ

LIST OF ABBREVIATIONS ⅺ

CHAPTER 1 INTRODUCTION 1

1.1 Introduction 1

1.2 Project Background 2

1.3 Problem Satement 3

1.4 Objective 4

1.5 Expected Result 4

1.6 Project Scope 5

CHAPTER 2 STYLES 6

2.1 Overview 6

2.2 Wire Arc Additive Manufacturing (WAAM) 6

2.3 Mechanical Behaviour of AISI 316 Stainless Steel 7

2.4 Microstructure Change of 316l Stainless Steel in Welding Process 8

2.5 Optimization of 316 Stainless Steel Weld Joint Parameters. 8

iv
2.6 Testing of 316L Stainless Steel in WAAM 9

2.7 Finite Element Method (FEM) By Using MSC Marc/Mentat 9

2.8 Gas Metal Arc Welding (GMAW) 11

2.9 Robotic Welding 13

2.10 Composition of SS316L 15

2.11 Distortion 16

2.12 Residual stress 17

CHAPTER 3 METHODOLOGY 19

3.1 Introduction 19

3.2 Problem Identification and Gathering Information 21

3.3 Preparing the Specimen 21

3.4 Welding Process 22

3.5 Finding welding parameter 219

3.6 Drawing of Simulation 24

3.7 Inspection and Testing of 316L Stainless Steel in WAAM 25

3.8 Chemical Composition Wire 316L stainless steel and Specimen of WAAM 30

3.9 Determine the Residual Stress on the Specimen WAAM 30

3.10 Analyse the result by comparing Experimental and FEM Simulation 30

CHAPTER 4 RESULT AND DISCUSSION 32

2.1 Welding Process 32

2.2 Simulation FEM 34

2.3 Hardness Test 39

2.4 X-Ray Diffraction (XRD) 40

2.5 Macrostructure 41

v
2.6 Energy-dispersive X-ray spectroscopy(EDX) 43

CHAPTER 5 CONCLUSION AND RECOMMENDATION 48

5.1 CONCLUSION 48

5.2 RECOMMENDATIONS 49

REFERENCE 50

APPENDIX 51

vi
 LIST OF TABLES

Table 2.0 Chemical composition of the austenitic stainless steel 316 and 15
316L
Table 4.0 Parameter of various welding. 33

Table 4.1 Result of hardness test by Hardness Vickers machine. 39

Table 4.2 Result of the residual stress for the WAAM specimen 40

Table 4.3 The result of the all size weld filler on the WAAM 42

Table 4.4 The chemical composition comparison of the wire and WAAM 46

product specimen with catalogue of SS316L.

vii
 LIST OF FIGURES

Figure 2.0 Figure 2.0: Set of the wire Austenitic Stainless Steel 316L 7

Figure 2.1 MSC Marc/Mentat Software 10

Figure 2.2 The double-ellipsoidal heat power density model proposed by 11

Goldak.

Figure 2.3 Illustration of GMAW process. 12

Figure 2.4 Schematic representation, (a, b, c) temperature vs stress during 18

welding d) final longitudinal residual stress.

Figure 3.0 Design of preparation of base plate 200mmx100mm8.5mm 21

Figure 3.1 Schematic diagram of robot-assisted CMT WAAM equipment (a) 22

and the overview of the deposited wall (b) by Jinguo Ge.

Figure 3.2 Clamping on the WAAM process. 23

Figure 3.3 Workspace for WAAM simulation at MSC Marc 25

Figure 3.4 Abrasive cutter for cutting process 26

Figure 3.5 Mounting machine 26

Figure 3.6 Grinding machine (left) and waterproof paper made of silicon 27

carbide.

Figure 3.7 Polishing machine (left) and alumina powder (right) 27

viii
Figure 3.8 Kalling’s No.2 solution for etching process. 28

Figure 3.9 Macrostructure machine 29

Figure 3.10 Vicker Harness Test Machine 29

Figure 3.11 Energy-dispersive X-ray spectroscopy(EDX) Machine 31

Figure 4.0 Comparison of four welding seams with various welding 33

Figure 4.1 Results of WAAM process by using normal and holding time of 34

316L filler material

Figure 4.2 The Double Ellipsoids Heat source parameter used on the MSC 35

Figure 4.3 The result of 3 String 10 Layer simulation 35

Figure 4.4 Distortion of high temperature simulation of WAAM 36

Figure 4.5 Distortion of normal temperature simulation of WAAM. 36

Figure 4.6 Appoint of nodes at every 3 layer of every string to determine 37

effective stress.

Figure 4.7 The graph of residual stress both simulation. 37

Figure 4.8 Simulation of WAAM without substrate for a results. 38

Figure 4.9 Result of effective stress at the base of WAAM simulation 38

Figure 4.10 The nine-point undergoing to the XRD 40

ix
Figure 4.11 Result of the residual stress for the WAAM specimen 41

Figure 4.12 The manual method measurement by used ruler in millimeter (mm) 41

Figure 4.13 Result of average of weld filler (experimental) 42

Figure 4.14 Result of size weld filler (Simulation) WAAM specimen. 42

Figure 4.15 The Chemical composition at the Bottom of WAAM 43

Figure 4.16 The Chemical composition at the Middle of WAAM 44

Figure 4.17 The Chemical composition at the Top of WAAM 44

Figure 4.18 The Chemical composition at the wire of SS316L 45

x
LIST OF ABBREVIATIONS

AM Additive Manufacturing
AISI American Iron And Steel Institute
CAD Computer-Aided Design
EDX Energy-Dispersive X-Ray Spectroscopy
FEM Finite Element Model
DT Destructive Test
HV Hardness Vickers
GMAW Gas Metal Arc Welding
GTAW Gas Tungsten Arc Welding
MLMB Multi-Layer Multi-Bead
MIG Metal Inert Gas
SAW Submerge Arc Welding
WAAM Wire Arc Additive Manufacturing
XRD X-Ray Diffraction Machines

xi
 CHAPTER 1

INTRODUCTION

1.1 Introduction

WAAM adapts the multi-layered welding as its basic operating model, similar
to a 3D printing technique. WAAM is able to produce components in less moment than
other procedures because of its complexity. These methods receive concern from the
manufacturing industry due to their opportunities for production of huge metal
materials with small price and fast lead time. Wire Arc Additive Manufacturing
(WAAM) enables greater opportunities of design and potential weight savings. AISI
316L has the largest welding ability among stainless steels and low carbon material,
carbide precipitation will have less chance of happening during welding, but the
mechanical features of anisotropy differ from the consolidation of the grain boundary in
various ways. Finite element process simulation arranges an appropriate manner to
research changing policies for some problem. Instead, the Wire Arc Additive
Manufacturing (WAAM) technique includes laboratory set-up and FEM simulation
with welding performance (e.g. surface finish, chemical composition, hardness test,
effective stress and macrostructure properties). In order to understand the fundamentals
of WAAM, the conduct of a single-string multi-layer structure is frequently investigated
with a concentrate on multiple components such as modelling, construction,
development and allocation of residual stress, differences in welding procedures and
many more.

1
1.2 Project Background

WAAM adapts the multi-layered welding as its basic operating model, similar to
a 3D printing technique. WAAM is able to produce components in less moment than
other procedures because of its complexity. These methods receive concern from the
manufacturing industry due to their opportunities for production of huge metal
materials with small price and fast lead time. Wire Arc Additive Manufacturing
(WAAM) enables greater opportunities of design and potential weight savings.

AISI 316L has the largest welding ability among stainless steels and low carbon
material, carbide precipitation will have less chance of happening during welding, but
the mechanical features of anisotropy differ from the consolidation of the grain
boundary in various ways. Finite element process simulation arranges an appropriate
manner to research changing policies for some problem.

Instead, the Wire Arc Additive Manufacturing (WAAM) technique includes

laboratory set-up and FEM simulation with welding performance (e.g. surface finish,
chemical composition, hardness test, effective stress and macrostructure properties). In
order to understand the fundamentals of WAAM, the conduct of a single-string multi-
layer structure is frequently investigated with a concentrate on multiple components
such as modeling, construction, development and allocation of residual stress,
differences in welding procedures and many more.

2
1.3 Problem Statement

Despite the high quality, there are some difficulties with respect to significant
arc-related heat outputs that lead in high residual stress. Simulation of the finite element
method offers an efficient manner to research modification policies for these issues.
The strain associated with the distortion move also decreases the residual stress. On an
original model of heat source, which interprets the potential power supply between
filler foundation materials and a modelling methodology for WAAM is anticipated. To
verify the effectiveness of the recommended modelling, an experimental
encouragement is carried out by comparing the measured distortions of a WAAM test
case with the simulated ones, attempting to emphasize the accuracy of the current
interpretation. In WAAM, the design strategy consists of a sequence of single welded
structures, one on the most, rotating cooling periods with deposition measures. Previous
study is concentrated from both the deposition of subsequent low carbon steel layers.
The process heating and cooling phases affect the microstructure and mechanical
characteristics of the product, which would have a large effect on issues including
product machinability and fatigue resistance. In our case, with regard to the results of
this task, how a robotic welding mechanism can assist in welding and establish the
welding parameters for the sample. The Wire Arc Additive Manufacturing (WAAM)
method therefore uses laboratory set-up and FEM simulation incorporating welding
performance (e.g. surface roughness, effective stress, chemical composition and
microstructure properties). The simulation and laboratory configuration comparative
will concentrate on all temperature stress hardening model for stainless steel fabric at
elevated temperature.

3
1.4 Objective

1. To determine the Wire Arc Additive Manufacturing (WAAM) parameter using

316L stainless steel.
2. To research the effect of multi-layer multi-bead (MLMB) imperfections of
Austenitic Cr-Ni stainless metal (316L) as filler and substrate material.
3. To generate a simulation model using MSC Marc / Mentat as FEM software to
compare with the laboratory experimental.
4. To analyse the laboratory sample by doing and Destructive Test (DT) in order of
welding performance.

1.5 Expected Results:

1. To better understanding how Wire Arc Additive Manufacturing (WAAM)

works with 316L stainless steel.
2. Finalize the appropriate parameter for Austenitic Cr-Ni Stainless Steel material
with less defects and distortions once used in plastic welding.
3. Be able determine a defects of multi-layer multi-bead (MLMB) when Austenitic
Cr-Ni Stainless steel is used as filler and substrate material.
4. Be prepared to achieve a satisfying outcome in monitoring the sample and the
specimen's mechanical characteristics.
5. To accumulate the finest model of simulation that will yield comparable results
with the preliminary test.

4
1.6 Project of Scope

The main objective of this research should be to achieve the greatest parameter
resulting in the smallest deformation and distortion from the Finite Element Method
(FEM) computer model and then comparison it with the experimental result to
investigate the welding performance so that it could be applied in actual application.

The scope of this project is:

▪ Austenitic Cr-Ni Stainless Steel (316L)

▪ Experimental function with ABB Robotic Welding to monitor unmatched

Engineering parameters

▪ Draw welding simulation in MSC Marc / Mentat

▪ WAAM specimen microstructure inspection

▪ Investigate mechanical characteristics and experimentation on the WAAM

sample

This overall project laboratory research will be finished at the Faculty of

Mechanical Engineering, UITM Shah Alam, Mechanical Workshop, Robotic Welding
Workshop, Strength and Material Laboratory. The welding technique to be used is
GMAW with complete Argon.

5
 CHAPTER 2

LITERATURE REVIEW

2.1 Overview

Application of austenitic 316L stainless steel material will be discussed in this

section on the growth of performance welding through inspection and composition-
based testing in previous research.

2.2 Wire Arc Additive Manufacturing (WAAM)

WAAM works for the production of wire exchange additives. It is a

combination of an electrical arc used as the origin of heat and wire as the feedstock.
Baker presented WAAM's first model in 1925, accompanied by Shocky and Ujiie.
However, it was only studied for additive manufacturing reasons after the 1990s.
Currently, WAAM construction uses conventional off-shelf heating devices: energy
supply heating, lamps and wire supplying systems. Either robotic systems or numerical
gateways regulated by a machine can provide motion. GMAW is the performance
method wherever necessary: the wire is the consumable electrode and its co-axiality
with the welding torch allows the route of the instrument simpler and quicker [4].
WAAM adheres the multi-layered welding as its fundamental operating model, similar
to a 3D printing technique. It generates components by coating of fabric deposition.
Because of its layout, WAAM is capable of producing components in less time than
other procedures. These techniques generate consideration from the manufacturing
industry due to their capacity to produce large metal components with small cost and
quick lead moment in manufacture.

6
2.3 Mechanical Behaviour of AISI 316 Stainless Steel

In our experiment, the main objective of the material research was 316L Stainless
Steel. In specific, the cognitive content selected must be directed and benchmarked. For
WAAM, austenitic stainless steels such as AISI form 316 are particularly important
because they are relatively expensive to process. Austenitic stainless steel, which is
used for a significant structure of stress machinery, maintains strong power and
outstanding ductility from cryogenic to high pressures. 316L austenitic, a common
structural material that serves the requirements of high-pressure vessels, pipes, valves,
and so on [3]. However, the mechanical behavior of 316L modifications in stainless
steel after pressure hardening and welding can also produce corrosion-sensitive grain
boundaries [4]. Without important fabric failures, near-net-shaped structures could be
generated, decreasing the cost of expensive metals such as Ni, Cr and Mo. For
engineering implementations, AISI 316 steel will have great intergranular corrosion
resistance, great grain corrosion resistance to most chemicals, salts and oils, and Mo
material will help to increase marine endurance. [5]. Tungsten inert gas or plasma
arc welding is actually currently used for metal processing. These processes depend on
internal wire processing for deposition accuracy. The Wire must always be supplied in
the same direction, which involves torch rotation, making robot programming more
complicated. [6]. AISI 316's low carbon variant, known as 316L, is essentially resistant
to autoimmunity (precipitation of grain boundary carbide).

Figure 2.0: Set of the wire Austenitic Stainless Steel 316L

2.4 Microstructure Change of 316l Stainless Steel in Welding Process

7
 Since most mechanical, physical and chemical properties are determined by
microstructure, the microstructures obtained during the production and treatment of
austenitic stainless steel must be characterize [5]. This research focuses on the
mechanical and microstructural characteristics of the annealing temperature. Aims of
the work were established mechanisms of occurrence of intermetallic sigma phase, and
determined how mechanical properties and impact energy of austenitic stainless steel
AISI 316L weld metal were affected by precipitation of sigma phase [7]. A large
number of dendrites are occupied with the microstructure of 316L stainless steel parts
made by WAAM, and the direction of growth is along the temperature gradient. The
heat dissipation direction is also perpendicular to the direction of the substratum, the
grain growth direction is the temperature gradient on the side.

2.5 Optimization of 316 Stainless Steel Weld Joint Parameters.

WAAM can produce parts in longer (time-efficient) moments and at relatively low
(cost-competitive) rates. This technology uses electrical arc to freeze copper wire as a
powerful method and can achieve a large feed rate. The literature also claims that this
technology is appropriate for the production of plastic parts with complicated system
and design, but the surface finish of the produced parts is comparatively low. [8].

Path scheduling in WAAM is a significant step. Parameters of the process such as:
a. Wire feed rate
b. Path of deposition
c. Speed of deposition
d. Power supply

All parameters must be carefully planned to obtain the highest feasible geometric
structures precision, ground quality, and mechanical efficiency of the manufactured
parts.

2.6 Testing of 316L Stainless Steel in WAAM

8
 The research facility result was a macroscopic analysis and evaluation of
metallographic hardness and microstructure. This was done for contradistinction to
have reference hardness. These samples were subjected to standard metallographic
techniques such as brushing and polishing, as well as point listing of the ferrite material
in the first and last beads as well as in the heat-affected region and base metal.
Mechanical learning is the most popular preparation technique. Successively thinner
abrasive substances are used to remove content from the bottom of the sample until the
required ground performance is attained. There are many separate tools for this grinding
and polishing that can meet different performance, capacity and reproducibility
requirements technique of systemic preparing is the simplest route to attain the real
structure. Therefore, sample preparing must obey appropriate directions for most
components. Different products with similar features (strength and ductility) will also
respond during the training stage and involve the same consumables. Hardness tests a
mixture of elastic, plastic, and fracture characteristics that combine yield stress,
Young's module, and fracture parameters. There is no single formula, however, that
provides the quantity of hardness as a percentage of the primary parameters. The best
way to do this is to provide some estimated interactions for certain groups of content.
The best approach to do this is to provide further estimated relationships for certain
associations of material. There is a very significant relationship between the Vickers
Hardness [HV] and the yield stress or tensile strength for relatively light metals and
steel, or including both.

2.7 Finite Element Method (FEM) By Using MSC Marc/Mentat

9
 Despite the latter result may seem inaccurate, it should be considered that material
data have been derived from literature, hence actual material behavior could be different
from the model one[4]. Furthermore, no tuning operation was carried out for what
concerns convection coefficients and heat source parameters, as it is usually performed in
works dealing with WAAM simulation. Despite its great benefits, WAAM components
are affected by severe distortions and residual stresses issues. Finite element process
simulation provides an efficient way to study mitigation strategies for such issues. MSC
Marc/Mentat is a FEM-based software which tends to be more commercialized compared
to SIMUFACT which is more specialized in a certain manufacturing process [10]. The
main feature of MSC Marc/Mentat is its ability to simulate a diverse options of
manufacturing process while being in the same platform. Its ability to model a geometry
without the help of 3rd party CAD program is what makes MSC Marc Mentat is a
competent FEM software for research purpose in virtual manufacturing environment.
MSC Marc / Mentat can import the geometry from other CAD programs as a model that
is being simulated, like SIMUFACT software. The welding measurements for the
experimental results would be simulated.

The standard heat source for this simulation was the double-ellipsoidal heat
density system proposed by Goldak, which has been widely used as the basis for

10
modeling heat transfer in arc welding operations for over thirty years. This strategy has
demonstrated to be highly efficient for a wide range of arc welding behaviors.
However, a double-ellipsoidal heat density expenditure is less appropriate for keyhole-
laser or electron-beam welding activities or in cases where arc welding requires position
within profound tight holes. The double-ellipsoidal range is expanded to a double-
ellipsoidal-conical heat density structure to correctly define temporary temperature
areas for a wider spectrum of geometries and welding procedures. The new improved
model was validated by comparing the anticipated heat welding speeds with those for a
single-pass electron beam weld and those evaluated in a multi-pass tight slide weld.
Outstanding arrangement was accomplished between anticipated and observed thermal
transients in both instances.

Figure 2.2: The double-ellipsoidal heat power

density model proposed by Goldak

2.8 Gas Metal Arc Welding (GMAW)

Many welding techniques are used in today's manufacturing industry, such as

SMAW, GMAW and many more. In this endeavor, GMAW is used as a welding
method in the manufacturing of the WAAM sample and also regarded as GMAW
welding or Metal Inert Gas (MIG). GMAW uses an electrical arc between the feedstock
and the wire electrode of the work piece. GMAW uses an equation between the metal
unit of a feedstock and the work piece. GMAW is a flexible method that can be applied
separately, semi-automatically or fully automatically.

11
 It is advantageous for many engineering applications because of this
complexity. GMAW has the lowest weld formation frequency compared to SMAW or
GTAW. In addition, when applied as a semi-automatic method, GMAW requires less
welder expertise.

Figure 2.3: Illustration of GMAW process.

For the first time in the USA in 1949, GMAW or MIG welding was patented for
welding aluminium. The flame and weld pool produced by a blank wire electrode was
protected by helium gas, which was readily available at that time. The method became
popular in the UK after 1952 for welding aluminium using argon as the shielding gas,
and for using CO2 for carbon steels. GMAW produces elevated deposition levels and
strong productivity.

Unfortunately, GMAW machinery is more complicated and usually less portable

than many other welding procedures. GMAW is frequently used to weld dense alloy
samples such as SS304L, SS308L and SS316L. The selection of shielding gas is critical
to establishing GMAW procedures. As a result, the shielding gas will have an important
effect on the arc and metal transition stability and, in particular, on the weld pool's
penetration behavior. Argon, oxygen and C02 mixtures are frequently used to safeguard
GMAW welding gases and distinctive gas mixtures may involve helium.

12
 Argon-based gasses are generally more sensitive to parameter settings relative to
CO2 and generate lower levels of spatter with plunge transition method. Because these
gasses are warmer, however, there is a greater risk of lack of fusion failures. Due to
high back-plasma forces, CO2 cannot be used in closed welding methods, usually
argon-based liquids comprising oxygen or CO2 are used. Because argon and helium are
inert gasses, the bottom of the as-deposited weld is due to be bright and shiny with
minimal oxidation.

Some parts of the GMAW equipment, such as the contact tip and filler wire conduit /
liner, have high wear and should be replaced periodically. A carried or filthy handle
may cause unpredictable wire flow, contributing to coil turbulence, or because the filler
wire to jam, recognized as a "chicken cage." If necessary, the wire handler should be
placed so that during the welding phase the weapon cable is almost directly.

2.9 Robotic Welding

Industrial robots or mechanized equipment have become more prevalent for elevated
quantity productivity, usually using robotic gas metal arc welding (GMAW). Welding
technology offers many benefits for all aspects, from increased efficiency and welding
accuracy to reduced production, labour and equipment costs. Robots are no longer only
appropriate for large manufacturers, but the advancement of a Robotic Welding
technology alternative also advantages large industries.

The use of robotics in welding procedures has many advantages;

a. Consistent and Repeatability

Manual welding needs a strong amount of expertise as well as intensity to achieve

accuracy and repeatability. A motorized welder can perform precisely the same welding
process on a continuous basis, 24 hours a day, seven days a week.

13
a. Safety

There are numerous safety hazards for welders, such as exposed to electrical shock,
smoke and damaging fumes, and flash burns throughout the face of the welders. With
the proportion of injuries recorded to Safe Work Australia rising each year, robotic
welders have also been shown to reduce the number of crashes for metal manufacturing
staff.

b. Quality

There are countless safety risks for welders, such as exposure to electrical shock, smoke
and harmful fumes, and flash burns throughout the welder’s body. With the percentage
of accidents reported to Safe Work Australia increasing each year, robotic welders have
also been shown to decrease the amount of accidents for metal manufacturing
employees.

c. Reduce Consumables

The weld size is determined by the manual welding operator and may result in a higher
weld than required. Robots are programmed to always be welded to the right joint
requirement length and size. It will also follow any complicated geometric design that
we already have.

d. Reduction in Weld Distortion

Distortion in a weld is caused by the growth and contraction of the welded metal and
adjacent base metal during the welding process heating and cooling cycle. Robotic
welders are tuned to properly size the weld to accommodate the joint requirements,
minimize the amount of weld passes and complete the process with speed to minimize
the heating of the surrounding metal which can expand and distort. The caption is
another style that is similarly essential. All captions are formatted using their
corresponding styles prepared in this model for statistics, tables and equations.

14
2.10 Composition of SS316L

The 316L stainless steel was superior for certain components opposed to other stainless
steels. Type 316 steel is a chromium-nickel austenitic stainless steel consisting of
between 2% percent and 3% percent molybdenum. Molybdenum material increases
corrosion resistance, increases pitting strength of chloride ion alternatives, and increases
strength at elevated heights. Type 316 stainless steel is particularly efficient under
acidic circumstances. This grade of steel is efficient in the safeguard against corrosion
of sulphuric, hydrochloric, acetic, formic and tartaric substances as well as acid
sulphates and alkaline chlorides.

Physical Properties of type 316 and 316L steels:

 Density: 0.799g/cm3
 Electrical resistivity: 74 microhm-cm (20 degrees Celsius)
 Specific Heat: 0.50 kJ/kg-K (0–100 degrees Celsius)
 Thermal conductivity: 16.2 W/m-k (100 degrees Celsius)
 Modulus of Elasticity (MPa): 193 x 103 in tension
 Melting Range: 2,500–2,550 degrees Fahrenheit (1,371–1,399 degrees Celsius)

A summary of the percentages of separate parts used in the production of form 316 and
316L steels:

Element Type 316 (%) Type 316L (%)

Carbon 0.08 max. 0.03 max.
Manganese 2.00 max. 2.00 max.
Phosphorus 0.045 max. 0.045 max.
Sulfur 0.03 max. 0.03 max.
Silicon 0.75 max. 0.75 max.
Chromium 16.00-18.00 16.00-18.00
Nickel 10.00-14.00 10.00-14.00
Molybdenum 2.00-3.00 2.00-3.00
Nitrogen 0.10 max. 0.10 max.
Iron Balance Balance

Table 2.0: Chemical composition of the austenitic stainless steel 316 and 316L

15
2.11 Distortion

Distortion or deformation throughout welding can happen due to standardized

growth and contraction throughout the welding and cooling phase of base metal.
Stresses shape in the weld as a consequence of size changes, especially if the weld is
constrained by the set components or other materials around it. If the limitations are
taken in part and can even contribute to weeping or fractures, these pressures can distort
the base metal. Obviously, distorting appropriately can be very expensive to reparation,
so avoidance is important. There are many factors that can cause distortion of welding
or cutting and it is very difficult to estimate the accurate amount of distortion that is
probable to occur. The degree of restriction, the heat and other characteristics of the
parent material are some of the variables that should be observed. Inherent factors due
to previous metalworking processes such as grinding, forming and bending, the
configuration of welding and accuracy of manufacturing. The very nature of the
welding process with the type of process, joint symmetry, preheat, and the number and
sequence of welds necessary.

Limitation of Distortion

The implications of weld deformation can never be completely eliminated, but by

following some practical measures as follows, maintain them to a minimal level:
 Reduction of steel welding quantities to avoid overfilling and continuous
heating Minimization of extraction weld runs
 The welds are properly positioned and balanced around the axis
 Use back move or avoid techniques for cutting short welds in the reverse path
 Use back move or avoid techniques for prolonging welds in the reverse direction
 The welding sequence is designed to prevent progressive shrinkages and shorten
the welding time

16
2.12 Residual stress

Welding has been implemented in many fields, including building, piping,

shipbuilding, aviation and aerospace, automotive, train, crop machinery, home
appliances, mining machinery, computer components and building materials. Welding
is a method that combines two or more metal components to form a single item and is
used to produce a powerful and safe bond that is heavier than other techniques of metal
bonding. Welding is a method involving the generation of localized heat from the origin
of moving water. The welding facilities are quickly cooled to the melting temperature,
accompanied by fast drying, which results in modifications in microstructure and
characteristics leading to residual stress. [10].
Residual stress in welded structures outcomes from non-uniform growth and
compression of welded fabric and foundation metal which occurs in non-uniform heat
allocation during the welding stage. Localized heating and rapid cooling depending on
welding residual stress [11]. Most of the residual stress discovered in welding parts is
damaging tensile stress that affects the welding parts negatively. But some scientists
have found that compressive residual stress can benefit the welding parts. Residual
tensile stress can split the welding element, while compressive residual stress can boost
the effectiveness of the product.
The main source of residual stress corrosion is shrinking, quenching and phase
transformation. Tensile residual stress occurs as the quenching and phase
transformation procedure affects compressive residual stress [12]. The welding element
includes tensile and compressive residual stress, but the location determines on their
allocation. Welding elements can be strengthened by specific therapy at certain
locations, possibly based on the documentation of residual stress distribution. To
enhance its effectiveness and decrease adverse effects on the welding element, it is
therefore essential to define the residual stress allocation of welding.

17
Distribution
Many factors affect remaining pressure allocation in welding components. Depending
on the residual stress effect, it has few variables that influence the allocation of residual
stress in welding components:
i. Before welding (manufacture and manufacture) the presence of residual stress
ii. Material properties (welded and metal parent)
iii. The geometry of the parts attached.
iv Restrain applied
v. Welding process
vi. Resulting welding operation

Figure 2.4: Diagram (a, b, c) temperature vs. pressure during welding (d) Ultimate
longitudinal residual stress.

18
 CHAPTER 3

METHODOLOGY

3.1 Introduction

This experiment comprised of programmable welding techniques to produce the

WAAM sample and mainly focused on the metallographic technique of the sample. In
this experiment, the first phase was to discover the best parameters for robotic welding.
The correct welding parameter could be guidance for FEM simulation by using MSC
Marc Mentat software. Knowledge of the welding specimen's visual performance test is
required to determine the specified value. The parameters were used to create WAAM
samples suitable for cutting and metallographic experiments were carried out to
investigate the microstructure and structure of the welded portion. Furthermore, to
decrease the effect of stress on the sample, another sample with a non-traditional
apparatus had to be censored. Otherwise, the final outcome was the actual experiment
compared with FEM simulation. The process flow is shown in the methodology graph
below for the complete test.

19
PROJECT METHODOLOGY (FLOWCHART)

START

Determine Objective, Problem Statement and Scope of

Project.

Performed literature review on the 316L stainless steel

behaviour on the welding process

Start process of setting the Optimum welding parameters

regarding the by research

Start the welding process on the specimen

Visual Inspection
NO

Preparing the Specimen for the Test

Testing and Inspection (to determine Surface Finish,

Hardness Vickers, Effective stress, Chemical
Composition and Microstructure)

Analyse the Result

Apply Result For Optimize Simulation through Marc

Mentat Software

Result Discussion and Conclusion

END

20
 Project Methodology is a method used to document the performance of the study. It
is important to have a suitable methodology plan in this project to become a guideline
to attempt to create the research more efficient and well designed. Process flow is
shown in the above flow chart.

3.2 Problem Identification and Gathering Information

Identify the student's scope of research or source material. Find an appropriate lecturer
at the end of the year to book the subject for the project. After that, gather all the
information from a source such as novels, newspapers, articles, blog, etc. The
understanding will be useful and essential in supporting the study so that the study can
be carried out effectively. The data would also be the thesis guideline or guideline. It is
also important to keep that the method was recognized by the past researcher.

3.3 Preparing the Specimen

The substance to be used is Austenitic Cr-Ni Stainless Steel 316L for this project.
Before exploring the best possible welding parameters, many specimens have to be
used. The Austenitic Cr-Ni Stainless Steel is supplied by the faculty and can be
discovered at the Faculty of Mechanical Engineering's Mechanical Workshop, UiTM
Shah Alam. The specimen's size is 200 mm x 100mmx8.5 mm.

Figure 3.0: Design of preparation of base plate 200mmx100mm8.5mm

21
3.4 Welding Process

ABB GMAW Robotic Welding situated at the Robotic Welding Workshop will perform
this method. Where the welding parameters such as temperature (A), wire feed (m /
min), voltage (V) and weld speed (mm / s) are closely selected, the method is important.
All parameters are required depending on the quality of the welding product and the
process has been manually and automatically monitored.

Figure 3.1: Schematic diagram of robot-assisted CMT WAAM equipment (a) and the overview
of the deposited wall (b) by Jinguo Ge.

The work flow of a robotic welding cell consists of a series of closely monitored steps.
These steps are:

1. Switch ON power supply, controller and shielding gas.

2. Set the part into the fixture and clamp it securely into place.
3. Set up the Start/End for multibead layers according size of weldfiller.
4. Select the appropriate program from the controller and set up our parameter.
3. Push the start button on the controller to begin work.

Specific functions and intricacies vary depending on the particular robotic welding cell
used, but most will follow this general procedure.

22
 Figure 3.2: Clamping on the WAAM process.

3.5 Finding welding parameter

The material to be used was Austenitic Cr-Ni Stainless Steel 316L. Many samples
should be used before discovering the optimum welding parameters. A mild steel form
of 100 mm x 200 mm x 9 mm was used to prepare the size of the sample. ABB GMAW
Robotic Welding situated at the Robotic Welding Workshop will perform this method.
Route preparation is an important phase. Parameters of the process such as:

A. Wire feed rate

B. Path of deposition
C. Speed of deposition
D. Power supply

The following mathematical formula is used in mechanical engineering to calculate

how much heat is necessary for welding and enables people to understand how to
undertake such calculations independently.
Mathematical Formula of P = Power of heat input
Welding heat input: - V = Voltage (V)
I = Current (A)
P = V x I x 0.06/s S = speed (s)

23
 All parameters must be carefully planned to achieve the best possible geometric
accuracy, surface quality, and mechanical performance of the manufactured parts. The
finding parameter uses the Metal Inert Gas (MIG) technique to determine the quality of
each weld seam.

3.6 Drawing of Simulation

The simulation will be drawn using software data MSC Marc / Mentat. The simulation
results will be used to evaluate the technique of experimental welding. The
measurements necessary to produce the design;
1. Geometric modelling and FEM meshing
2. Assigning clamping and bearing
3. Assigning materials
4. Determining the weld path line
5. Defining welding parameters
6. Heat source modelling
7. Load case setting and set the points of monitoring
8. Running the simulation
9. Result and post-processing

Since the WAAM simulation requires a multi-pass welding sequence, the number of
similar procedures should be repeated depending on how much layer and string has
been added in the FEM WAAM simulation. A 10 levels of weld beads are introduced in
this study, which shows that the number of procedures to be performed is 10 times
before moving to the responsibility condition configuration.

24
 Figure 3.3 : Workspace for WAAM simulation at MSC Marc

3.7 Metallographic of WAAM Specimen

In order to study the microstructure of the WAAM specimen, this process will be
carried out in the Material Science Lab. The cutting, grinding, polishing and etching
method will be performed and the Axial Plane Optical Microscope will investigate the
specimen's microstructure. Welding technologies indicated for evaluation are in terms
of welding quality (e.g. surface finish, Vickers hardness, chemical composition,
appropriate microstructure stress and characteristics).

3.7.1 Cutting Process

Abrasive cutter and Water Jet Cutting are used to perform this method. The WAAM
sample was sliced using 10 mm thick abrasive cutting for the macrostructure and
hardness test). The sample was then slice using a 6 mm water jet cut to reduce the stress
on the sample to identify residual stress and also to verify the chemical composition of
the WAAM specimen.

25
 Figure 3.4: Abrasive cutter for cutting process
3.7.2 Mounting process

The specimens were installed during the grinding and polishing process to create it easy
to preserve the sample. Hot mounting is selected because compared to cold mounting it
requires smaller moment to execute. The technique for energy-dispersive X-ray
spectroscopy (EDX) focusing on the wire austenitic stainless steel.

Figure 3.5: Mounting machine

3.7.3 Grinding process

This technique is performed by using the grinding machine. Using waterproof

sand paper, 280 carbon carbide started with 320, 400, 600 and lastly 1200 with 5-6
minutes each, the sample is grinded from the lowest lattice. In the slicing stage, these
processes are performed to eliminate scratch on the sample layer.

26
 Figure 3.6: Grinding machine (left) and waterproof paper made of silicon carbide

3.8.4 Polishing process

To conduct this technique, a polishing equipment has been used. The grinded
samples are polished with alumina powder starting with the bigger size of 9μm,
followed by 5μm, 3μm and finally variable size of 1μm. It took about 5-6 minutes for
each process to obtain a shiny surface to reveal the specimens ' microstructure before
etching.

Figure 3.7: Polishing machine (left) and alumina powder (right)

27
3.8.5 Etching process

Using the No.2 solution from Kalling, samples are etched for 3-6 seconds. It is possible
to precipitate the specimen over etch to regrind as if the surface is burned and it is
impossible to observe the microstructure if the etching time is too short.

Figure 3.8: Kalling’s No.2 solution for etching process

The experimental result required to be cut is a surface for metallographic

hardness testing and micro-structure visualization. One cross section of the wall from
the weld filler specimen was sliced perpendicular to the inspection direction of the layer
length, measurements of Vickers pyramid hardness (1 kg HV strength) and description
of the macrostructure. These samples have been subjected to conventional
metallographic methods such as grinding and polishing, as well as counting etching of
the first and last bead size weld filler point. A hardness test was carried out to determine
the component strength to achieve the mechanical characteristics of the parts.

Subsequently, specimen was accompanied by a macrostructure device to define

the size of each multibead weldfiller for comparison on the FEM simulation. The
technique of etching can easily differentiate any size of weldbead. The macrostructure
identifies and adjusts some concentrate on a large scale. By checking the visual size, the
standard measuring tool used manual method to measure the quantity weld filler.

28
 Figure 3.9 : Macrostructure machine

The hardness test was carried out using the vicker harness testing machine. The
hardness test to measure the indenter's penetration depth or the size of the left
impression of an indenter. A load of 1 kg was applied to each weld bead by the
effective Vickers hardness test. The load applied in each weld filler is appropriate for
evaluating the competency of the hardness of our specimen. The test results must be
able to compare the measurement of the physical hardness test.

Figure 3.10 : Vicker Harness Test Machine

29
3.8 Chemical Composition Wire 316L stainless steel and Specimen of WAAM

After the welding has been completed, the specimen's chemical composition
shall be identical to the stainless 316L wire feed. As we understand, the WAAM and
316L stainless steel wire welding method has to be carried out in two samples. The
entire specimen was trimmed using used water jet machines and a thickness
measurement of approximately 25 mm for the welding process specimen. But the actual
316L wire on these machines was difficult to differentiate physically. The wire was
mounted using Simplimet 2000. A certain process of grinding, polishing and etching is
necessary to make the clear surface available for the determination of the wire. Set the
two samples on the EDX device, machined and brought out with the assistance of a
laboratory technician. Stimulated these machines and to proceed with the specimen
randomly we had to identify six points. This requires us to identify the chemical
composition to be defined in the experiment.

3.9 Determine the Residual Stress on the Specimen WAAM

Residual stress is the internal stress allocation that is bound into a product. These
pressures happen even after the removal of all internal charging powers. The WAAM
sample method should determine the residual stress with links. The sample must be set
on X-Ray Diffraction devices (XRD). The rough cutting process must be implemented
to the machines to be corrected in this circumstance. Non-traditional devices find the
cutting toll and complete with water jet because the less stress on the samples can
happen. Compressive and tensile pressure was usually abandoned by the system
engineering and machinist. The nine spot was placed in the sample on every 3 layers of
each string to determine the residual stress.

30
 Figure 3.11 : Energy-dispersive X-ray spectroscopy(EDX) Machine

3.10 Analyse the result by comparing Experimental and FEM Simulation

After undergoing the experimental and FEM simulation, both method necessary
to compare the final result for the observe the differentiate. The result will show the
similarity on the both method and validate the result accepted or rejected. For the
distortion, the comparison occurs on two simulations which are normal plasticity and
high plasticity at the flow curve. Besides, the effective stress has taken three position
which are on the bottom, middle and top specimen after cut on the half of the WAAM
specimen. Lastly, the comparison of the chemical composition has been taken on the
WAAM specimen, wire 316L stainless steel and also catalogue of the austenitic
stainless steel 316L. All result necessary to be taken for the achieve of the objective of
this research.

31
 CHAPTER 4

RESULTS AND DISCUSSION

4.1 Welding Process

This method will be performed by ABB GMAW Robotic Welding at the Robotic
Welding Workshop. Close selection of welding parameters such as current (A), wire
feed (m / min), voltage (V) and welding speed (mm / s) is important. The test WAAM
with SS316L started to discover the best welding parameters and figure out what
configuration the weld seam has with the distinct welding parameters. The welding
parameters used are shown in the table: -

32
 Figure 3.1.1 : Comparison of four welding seams with various welding

1 2 3 4
Figure 4.0 : Comparison of four welding seams with various welding
Current 174 A 172 A 179 A 174 A

Voltage 19.8 V 19.8 V 19 V 20.0 V

Power 3.4 kW 3.4kW 3.2kW 3.1kW

Weld speed 5mm/s 5mm/s 5mm/s 3.2 mm/s

Wire feed 6.0m/min 6.4m/min 4.6m/min 6.5m/min

rate

Gas 100% Argon 100% Argon 100% Argon 100% Argon

33
 The experimental beginning with WAAM part welding with 10 layers and 3
strings. At the first examination we attempted to weld the whole portion without
holding time and the result shows very bad surface as well as the material goes down.
For the next experiment, the surface was then applied for two minutes of holding
moment for each layer, and the entire geometry looks much better. Because of the effect
of hot cracking, the temperature for the SS316L multi-layer welding process should not
exceed 150 ° C.

Figure 4.1: Results of WAAM process by using normal and

holding time of 316L filler material

4.2 Simulation FEM

On this simulation, all features and parameters were accompanied by the actual
test 3 String 10 layers on the WAAM product. The parameter used the same for the
experimental that used the power supply of 3.4 kW. Simulation also uses the table, plate
and weld bead in millimetres (mm) of real size. In addition, this model is also assigned
by both the real four clamping. It also included the load case holding time of 2 minutes.

34
 Figure 4.2: The Double Ellipsoids Heat source parameter used on the MSC
Marc/Mentat.
In my case, the two separate temperature simulations need to operate on the
MSC Marc Mentat software. The standard and high temperature on the flow curve
should determine the outcome of their comparison. It was therefore essential to modify
some temperature at the aflowmat of the MSC Mar Mentat. After some simulation
testing, thermal expansion is the main consideration in controlling the different
temperature. Thus, normal temperature thermal expansion is 2500K−1 and high
temperature increase to 3000K−1. Finally, both simulations complete with the right exit
number of 3004.

Figure 4.3: The result of 3 String 10 Layer simulation

35
 In this simulation, the distortion result was determined by a certain point on the
specimen. The note depends on the total data needed for this simulation. In this case,
seven points were taken on the specimen's width and the curve shows the distortion
condition. After that, the MSC Marc Mentat software clipboard can be copied to Excel
and the graph can be interpreted using mat-lab software. Therefore, for the purposes of
comparison, both normal and high temperature flow curve was used on mat lab
software.

Figure 4.4: Distortion of high temperature simulation of WAAM.

Figure 4.5: Distortion of normal temperature simulation of WAAM.

Based on the graph, the difference between the two simulations is roughly 0
because the price is only 0.0001. It did not have an enormous effect on the distortion at
the elevated fluid curve temperature. Furthermore, according to the both distortion
graph, the two simulations are also almost the same. It also happens to both progression
on the equal von misses. Next, the outcome simulation concentrates on residual stress
on the multi-bead layer of the WAAM specimen. So the simulation was done every 3
layers at each string and the procedure applied to the graph to demonstrate the possible
result, although it was compressive or tensile stress. It simple to determine both stress

36
which are compressive stress shows negative (-) result and tensile stress show positive
result (+).

Figure 4.6: Appoint of nodes at every 3 layer of every string to determine effective stress.

RESIDUAL STRESS 3S10L

250 3rd Layers

6th Layers
200
Stress Reliability Limit MPa

9th Layers
150

100
(+) Tensile
Residual
stress
50

0 (-)
0 5 10 15 20 25
Compressive
Width of weld filler (mm)
Residual
stress
Figure 4.7: The graph of residual stress both simulation

Because only 0.0001 is different, both simulations demonstrate the same result.
Therefore, the results are expected to be the same. The graph shows that only the
tensile stress (+) exists at WAAM modelling. Theoretically, the high tensile stress on

37
the middle welding may occur, but the stress on that position is difficult to transform
on the multi-bead welding layer.

Essentially, the effective stress of the need to be cantered determines because

the manufacturing process of WAAM as a product. Together with the contrast, the
other simulation was developed to assess the effective stress at the item foundation
without the substrate and the section whether it has an impact or not.

Figure 4.8: Simulation of WAAM without substrate for a results

Effective Stress at the Base Product

100
90
Stress Reliability Limit MPa

80
70
60
50
40
30
20
10
0
0 5 10 15 20 25
Width of weldfiller

Figure 4.9: Result of effective stress at the base of WAAM simulation

In fact, the stress occurs when not getting a bunch of stress relative to effective
stress with complete heating velocity depending on the WAAM item. Although the
residual stress at the base requires high stress depending on the multi-bead layer, the
residual stress is still below that complete heating level.

38
4.3 HARDNESS TEST

Hardness testing performed using Wire Arc Additive Manufacturing (WAAM) with
Vickers hardness inspection instruments for each layer of multiplayer welding. The
table shows that the Hardness Vickers device relocated the result of the hardness test to
the 10Layers 3String.

STRING 1 STRING 2 STRING 3

1S1L 161.3 1S1L 178.3 1S1L 166.8
1S2L 148.3 1S2L 158.8 1S2L 149.8
1S3L 188.8 1S3L 168.9 1S3L 142.9
1S4L 153.5 1S4L 181 1S4L 156.2
1S5L 187.5 1S5L 179.1 1S5L 160.5
1S6L 207.9 1S6L 195 1S6L 161
1S7L 218.1 1S7L 186.7 1S7L 170
1S8L 220.8 1S8L 175.6 1S8L 202.4
1S9L 208.4 1S9L 193.1 1S9L 177.4
1S10L 151.3 1S10L 163.7 1S10L 155.2
Vickers Hardness Test (Diamond Indenter)
Load = 1 Kg

String 1: - String 2: - String 3: -

Min: 148.3 HV Min: 158.8 HV Min: 142.9 HV
Max: 220.8 HV Max: 193.1 HV Max: 202.4 HV

Roughly, the result shows Vickers Hardness Test for every string was
approximately on each other’s. According to the result, string 3 shows that have highest
and lowest of Vickers hardness result compare to other string but was not having a lot
of different on each string. This outcome has thus been recognized to assess the
characteristics of material such as strength, ductility and wear resistance, and helps to
Table 4.1: Result of hardness test by Hardness Vickers machine.
determine 316L material by referring to the hardness of the data type.

39
4.4 X-Ray Diffraction (XRD)

The outcome of X-Ray Diffraction (XRD) display was distinct from the
simulation's residual stress. It required two hours for each node to undergo the
method. In addition, Bragg diffraction limits need to be fixed for the angle at the
start of the residual stress. The result also indicates the implementation of the
WAAM specimen. The level location at the bottom, centre and top of the
simulation is represented by each three nodes so that the result can be compared.

Figure 4.10: The nine-point undergoing to the XRD

Node Position String 1 String 2 String 3

3rd Layers 3237.56 540.97 796.91

6th Layers 197.16 -175.83 -697.78

9th Layers 2487.21 2005.01 -311.66

40
 RESIDUAL STRESS 3S10L
3500 3237.56 3rd Layers

3000 6th Layers

2487.21
Stress Reliability Limit

2500
2005.01 9th Layers
2000
1500
796.91
1000 540.97 (+) Tensile Residual
500 197.16 stress
1 2 3 4 5
-175.83 -311.66
0
0.5 1 1.5 2 2.5 3 3.5 4 4.5 -697.78
5 5.5
-500 (-) Compressive
-1000 Residual stress
Strings

Figure 4.11: Result of the residual stress for the WAAM specimen.

Based on the graph, the residual stress is correctly distinguished due to

effective simulation stress. There is no compressive stress for the fifth phase, but
there is some compressive stress on the six and nine strands at the bottom of the
node. As we know, for specimen only 6 mm can be conducted by limiting the
XRD device. Therefore, the processing method of the specimen could result in
compressive residual stress.

4.5 Macrostructure

The macrostructure process conducted was to determine similarity of the actual

size by experimental and simulation size of every weld bead. The dimension on
millimetre for each weld bead. The measurement was performed manually using
the macrostructure machine using the manual technique (ruler).

41
 Figure 4.12: the manual method measurement by used ruler in millimetre (mm )

1 String (mm) 2 String (mm) 3 string (mm)

L H W L H W L H W
1 2 6 1 2 5 1 2 7
2 3 6 2 2 8 2 2 7
3 2 5.5 3 2 8 3 2 6
4 2 5 4 2 8 4 2.5 5
5 2 6 5 2 7 5 2 4
6 2 6 6 2 7 6 2 6
7 2 5.5 7 2 7 7 2 5
8 2 6 8 2 7 8 2 6
9 2 6 9 2 6 9 2 6
1 4 6 1 4 6 1 5 9
0 0 0

Table 4.3: The result of the all size weld filler on the WAAM
specimen
The weld filler dimension takes 30 parts of each string and the total dimension
for the weld filler size. After that, the average weld filler was calculated to be compared
on the design weld filler on the FEM simulation

Figure 4.13: Result of average of weld filler (experimental)

7.5 mm
2.5 mm

Figure 4.14: Result of size weld filler (Simulation) WAAM specimen.

42
 The average of size weld filler shows that the similarity approaches to the size
weld filler design on the FEM Simulation. So it was being able to accept on the actual
Wire Arc Additive Manufacturing (WAAM) process.

4.6 Energy-dispersive X-ray spectroscopy(EDX)

Next, the EDX method for wire SS316L and sample was performed. It was to
follow the outcomes ' chemical structure. The six points randomly designate the
surface of the SS316L wire and the surface of the specimen in the bottom, middle
and top. At each sample result, periodic table elements C, Si, Mo, Cr, Mn, Fe,
and Ni were called.

Bottom

Figure 4.15: The Chemical composition at the Bottom of WAAM

specimen

Middle

43
Figure 4.16: The Chemical composition at the Middle of WAAM
specimen

Top

44
Figure 4.17: The Chemical composition at the Top of WAAM specimen

Wire

Figure 4.18: The Chemical composition at the Wire of SS316L

45
 The outcome from each specimen surface (bottom, middle, top and wire) has
now been performed on table 4.4. It produces it simpler for each component to
distinguish the percentage of weight. So it allows the proportion recognizing the
varying parts with the catalog of particular austenitic stainless steel 316L.

46
 CATALOG WIRE BOTTOM MIDDLE TOP

CK 0.01 0.4 0.7 1.1 1.1 0.8 0.7 0 0.2 0.2 0.2 0.1 0.2 1.7 1.1 1 0.6 2.5 3.9 1.7 5.4 13.1 6.7 10.7

Average 0.8 0.15 1.38 6.916666667

SiK 0.9 0.4 0.7 0.9 0.7 0.8 0.8 0.7 0.7 0.8 0.9 0.3 0.7 0.8 0.6 0.7 0.6 0.8 1 0.6 0.8 0.6 0.7 0.7

Average 0.716666667 0.683333333 0.7 0.733333333

MoL 2.6 0.7 1.3 1.4 1.3 1.4 1.1 0.1 0 0.1 0.2 0 0.1 0.1 0 0 0.1 0 0.3 0.2 0.1 0.1 0.1 0.1

Average 1.2 0.083333333 0.04 0.15

CrK 18.4 18.4 17.9 17.6 17.4 17.7 17.4 18.8 18 17.9 20 21.1 18.7 18.6 18.8 18.6 19 18.3 17.6 19.2 17.5 16.4 17.5 17

Average 17.73333333 19.08333333 18.66 17.53333333

MnK 1.8 2.6 2.5 2.6 2.3 2.1 2.5 2.5 2.5 2.7 3.4 4 2 2.8 2.4 2.5 2.5 2.4 2.7 2.2 2.4 2.4 2.1 2.5

Average 2.433333333 2.85 2.52 2.383333333

FeK Balance 68.8 67.9 67.5 66.2 66.6 67.9 65.5 66.7 67 67.6 66.5 62.7 67 61.7 58.9 63.8 59.7

Average 67.48333333 66.66 62.3

NiK 12.2 12.8 11.6 12 12.2 10.6 12.3 9.1 10.7 10.9 9 7.8 10.4 10.5 10.3 10.1 9.5 9.5 11.8 9 12 8.6 8.9 9.3

Average 11.91666667 9.65 9.98 9.933333333

Wire and WAAM 3 String 10 Layers specimen of 316L stainless steel chemical composition

47
 As a result, we can see the comparison of the wire and WAAM product between the
SS316L catalog and the actual SS316L product. On this methodology, the real item needs to
emphasize the carbon amounts because on the SS316L it was primary symbolic ' L ' which
means low carbon steel. Unfortunately, with catalog guidelines, it had a big difference in carbon
content at actual Stainless Steel 316L. The measurement may be subjected and the sample might
not have been well prepared. The unpredictable carbon result may happen because the etching
option was not appropriate for the high carbon weight ratio defect 316L sample. However,
another element still accepted as a result is Nickel and Manganese. The performance of
austenitic stainless steel remained representative.

48
 CHAPTER 5

CONCLUSION AND RECOMMENDATION

5.1 CONCLUSION

New technology improvement in the manufacturing of complex formed components by

well-established electric Wire Arc Additive Manufacturing (WAAM) in this research. The value
of the item generally refers to the parameter used on automatic welding and is essential to check
the value by visualizing the welding performance with some understanding. An Austenitic Cr-Ni
Stainless Steel 316L already used in WAAM with great outcomes, so it can prove the value
through the destructive test that it has achieved. The small weld filler separates between actual
and simulation. Furthermore, the specimen was subjected to residual stress deformation after
welding utilizing X-RAY Diffraction (XRD). However, the limitation preparation and advance
technology in our laboratory cannot generate the outcome precisely for the FEM simulation.
With the exception of waterjet cutting for the XRD technique, nearly researchers recommend
that electroplating methods are used to help ensure that the stress of welding sometimes doesn't
coincide with other stresses. Besides, Energy-dispersive X-ray spectroscopy (EDX) was
performed on the wire and WAAM product but the carbon element was performed on the
specimen. Attributable to some variables as well as sensitivity of the item itself and perhaps
unavailability of preparing before applying the EDX technique. However, the result still has

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similarities with certain major elements such as chromium, manganese and nickel. Nevertheless,
the research will be more detailed and effective when conducting the experiment with high-tech
machine and tool method.
For future studies, if the experimental and simulation existed by the correct method, it
could expand the additive manufacturing sector. Since the use of the SS316L in the marine and
aerospace industries was obviously the high-quality products.

5.2 RECOMMENDATIONS

Every nation has now been incorporated into Industry 4.0 and additive manufacturing has
been incorporated into components. Automation in the welding method should also be
considered throughout the sector and applied in Malaysia production. WAAM is a technology
capable of decreasing mass production time and, most significantly, because it does not involve
moulds to produce parts and customize them into autonomous construction, it can reduce
manufacturing costs. There are few possible incentives to encourage the performance of the
research in the future.

UiTM Shah Alam's Faculty of Mechanical Engineering (FKM) should suggest building
additional method welding equipment on the robot apart from GMAW on its own. In industry,
welding processes such as GTAW, SAW and other processes have always varied widely in their
ability to match manufactured products with GMAW processes. In fact, the student can practice
the robot with and some advanced welding processes to encourage the student to have a good
understanding of welding on the additive manufacturing to start practicing using this robot as a
basis to familiarize himself with this technology before entering the industry.

Since one and only robot is available in the particularly developed welding workshop for
the automatic welding technique, any robot problem or breakdown could affect the study
schedule. In addition, the robot's maintenance costs are very costly. An excellent servicing
program will help to ensure that the robot is in good condition and always prepared for the
testing stage. The technician conducts programmable welding corrective and preventive
maintenance and provides substitute components of high quality. The manager of robotic

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welding can then provide guidance for the use of robotic welding. A well-planned timetable for
robot use should have been designed by professors. In addition, a technician should always be
prepared to monitor the student's training in order to avoid any mistakes or unwanted situations
that interrupt the robot's situation.

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 REFERENCES

[1] R. Acheson: ‘Automatic welding apparatus for weld build-up and method of achieving
weld build-up’; US patent no. 4 952 769 1990. Gibson, D.W. Rosen, B. Stucker, Additive
Manufacturing Technologies: 3D Printing.

[2] S. W. Williams, F. Martina, A. C. Addison, J. Ding, G. Pardal, and P. Colegrove, “Wire þ

Arc Additive Manufacturing.” Rapid Prototyping, and Direct Digital Manufacturing, 2nd
ed., Springer, New York, 2015.

[3] L. Ji, J. Lu, C. Liu, C. Jing, H. Fan, and S. Ma, “Microstructure and mechanical properties
of 304L steel fabricated by arc additive manufacturing.” School of Mechanical
Engineering, Beijing Institute of Technology, Beijing, Zhongguancun south Street,
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[4] R. K. Desu, H. Nitin Krishnamurthy, A. Balu, A. K. Gupta, and S. K. Singh, “Mechanical

properties of Austenitic Stainless Steel 304L and 316L at elevated temperatures,” J.
Mater. Res. Technol., vol. 5, no. 1, pp. 13–20, Jan. 2016.

[5] F. Martina, J. Mehnen, S. W. Williams, P. Colegrove and F. Wang:‘Investigation of the

benefits of plasma deposition for the additive layer manufacture of Ti–6Al–4V’, J. Mater.
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[6] S. Kožuh *, M. Goji´c , L. Kosec “Mechanical properties and microstructure of austenitic

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[7] Sedriks AJ. Corrosion resistance of austenitic Fe–Cr–Ni–Mo alloys in marine

environments. Int Mat Reviews 1982;27:321–53.

[8] Magnus Eriksson,*, 1, Malin Lervåg2 , Camilla Sørensen2 , Andreas Robertstad2 , Bård
M. Brønstad2, “Additive manufacture of super duplex stainless steel using WAAM”
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[9] S. Hassan, L. Antunes, and J. Pavón, “Mentat: A data-driven agent-based simulation of

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[10] Nurul Syahida Mohd Nasir, Mohammad Khairul Azhar Abdul Razab, Sarizam Mamat,
Muhammad Iqbal Ahmad “Review on Welding Residual Stress” in Advanced Materials
Research Cluster, Faculty of Earth Science, University Malaysia Kelantan, Jeli, Kelantan,
Malaysia. Vol. 11, No. 9, May 2016

[11] J. T. Assis, V. Monin, J. R. Teodosio and T. Gurova. 2002. X-ray analysis of residual
stress distribution in weld region. Advances in X-ray Analysis. 45: 225-231.

[12] V. I. Monin, T. Gurova, X. Castello and S. F. Estefen.2009. Analysis of residual stress

state in welded steel plates by X-ray diffraction method. Reviews on Advanced Materials
Science. 19: 172-175.

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 APPENDIX A
SAMPLE APPENDIX 1

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