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Thesis Fyp
Thesis Fyp
in term of scope and quality for the purpose of awarding the Bachelor of Engineering
(Hons) Mechanical.”
Signed : ..................................................
Date : ...................................................
Supervisor
Dr Wan Emri Wan Abdul Rahman
Senior Lecturer
Faculty of Mechanical Engineering
Universiti Teknologi Mara (UiTM)
40450 Shah Alam
Selangor.
Signed : .............................................
Date : .............................................
Co-Supervisor
Prof. Dr. Ing. Yupiter HP Manurung
Senior Lecturer
Faculty of Mechanical Engineering
Universiti Teknologi Mara (UiTM)
40450 Shah Alam
Selangor.
“I declared that this thesis is the result of my own work except the ideas and
summaries which i clarified their sources. The thesis has not accepted for any degree
and is not concurrently submitted in candidature of any degree.”
Signed : ......................................................
Date : ......................................................
DECEMBER 2018
ACKNOWLEDGEMENT
I’m very thankful for everyone that supported me, for i fave completed my
final year project effectively and moreover on time.
Last but not least, special thanks for my lovely parents for their support
financially and mentally throughout this project. May The Almighty God bless and
repay your kindness.
ABSTRACT
CONTENT PAGE
TITLE
ACKNOWLEDGEMENT
ABSTRACT
LIST OF TABLES
LIST OF FIGURES
LIST OF ABBREVIATIONS
CHAPTER 1 INTRODUCTION
1.1 Introduction
1.2 Background of Study
1.3 Problem Statements
1.4 Objectives of the Study
1.5 Scope of Work
3.1 Introduction
4.1 Overview
4.2
4.3
4.4
4.5
4.6
5.1 Conclusion
5.2 Recommendation
REFERENCES
APPENDICES
LIST OF TABLES
LIST OF FIGURES
LIST OF ABBREVIATIONS
CHAPTER 1
INTRODUCTION
1.1 Introduction
The main question when performing this project is how a system of robotic
welding can help in welding and determine the welding parameters for the specimen.
The WAAM specimen that made off single bead with multi-layered will be studied
focusing on the microstructure development when the welding layers are increasing.
i. To obtain the best parameters of robotic welding when Stainless Steel 316L is
used as the filler material and mild steel as the base material to fabricate the
WAAM.
i. To study the grain growth of the microstructure of the single string with
multi-layered WAAM
ii. To study the heat distribution during the WAAM process.
1.5 Scope of Work
The experimental work of this project will be done at the Mechanical Workshop,
Robotic Welding Workshop and Material Laboratory located at Faculty of
Mechanical Engineering, UiTM Shah Alam. The welding process that will be use is
GMAW with Argon.
CHAPTER 2
LITERATURE REVIEW
METHODOLOGY
3.1 Introduction
START
NO
VISUAL
INSPECTION
THESIS WRITING
END
D
3.3 Gathering information
The parameters used for the robotic welding process in the preparation of the
WAAM specimen were obtained by experimental practices. As SS316L is expensive
and limited sources of the material in the workshop, hence cheaper material; stainless
steel 304L and 308L were used as practices to obtain the nearest parameters. After
successfully obtained the best parameters, the parameters were then used as
references in finding the parameters for SS316L: since Austenitic Cr-Ni Stainless
steel family have nearly the same characteristics and properties.
In this study, Austenitic Cr-Ni SS316L is used as the filler material and mild
steel is used as the base material. The dimension of the plate used as the base
material is approximately 300mm x 97mm with the thickness of 8.5mm.
The ABB IRB 2400/16 is the robotic welding used for this experimental
process equipped with GMAW power source KEMMPI Pro Evolution ProMIG
540MXE. The plate is clamped at all corners to minimize the distortion of the plate.
Figure 3.3: Clamping of the base material
The robot was programmed to weld a WAAM specimen of single bead that
consist of 5 layers with different length. The arc end of the layers is 25mm from the
right end of the plate.
Table 3.1: Position of the arc start and length of the weld
Arc start position form the left end of Length of the weld
the plate (mm) (mm)
25 250
75 200
125 150
175 100
225 50
Fifth layer
Fourth layer
Third layer
Second
layer
First layer
Base Material
Figure 3.4: Diagram of WAAM specimen after being welded on the base material
Parameter Value
Voltage (V) 19.8
Current (A) 172
Welding Speed (m/min) 6.4
The welds were let to cool for 2 minutes before perform another layer above
them except for 2nd layer with holding time approximately 5 minutes.
The thermocouples were connected to Kyowa data logger and to the plate
(base material). The first channel was attached at 10mm beside the expected weld
bead and 10 mm from the first arc start point. The second channel was attached at the
middle with 10mm beside the expected weld bead. Meanwhile the third channel was
attached at 10mm from the expected weld bead and 10mm from the arc end point.
The data logger was connected to a computer to record the reading.
Figure 3.5: Connection of thermocouples and data logger
Figure 3.6: WAAM specimens (top from left: 1 layer, 2 layers, Centre: 3 layers,
Bottom from left: 4 layers and 5 layers)
This process is done by using abrasive cutter. The WAAM specimen is cut
into five specimens, at the middle of each arc start of the layers.
Figure 3.7: Abrasive cutter (left) and the marking before cutting process (right)
Figure 3.9: Grinding machine (left) and waterproof paper made of silicon carbide
This process is done by using polishing machine. The grinded specimens are
polish by using alumina powder with different size started from the large size, 9µm,
followed by 5µm, 3µm and lastly 1µm. Each process took around 5-6 minutes in
order to get a shining surface before proceed with etching process to reveal the
microstructure of the specimens.
First layer
Base metal
Second layer
Third layer
Base metal
Fifth layer
Fourth layer
Third layer
Second layer
First layer
Base metal
4.1 Introduction
For 1 layer, the upper zone shows that the grain size formed were large
compare to the lower zone. The delta ferrite formed along the austenite grains. The
formation of the delta ferrite are continous and form a cellular grain of austenite.
For 3 layers, the boundary between the layer is clearly seen as the grain
between the layer are different in size and orientation. Meanwhile, the upper zone of
second layer shows less grain formation as the delta ferrite break up. The lower zone
of the third layer shows massive grain formation with different orientation compare
to the other zone.
Figure 4.4 Transition area of 1st layer and 2nd layer in 3 Layers WAAM
Figure 4.5: Transition area of 2nd layer and 3rd layer in 3 Layers WAAM
In the first layer, the grains size in the upper zone were reduce compare to
Figure 4.1 when they are in 1 layer specimen. At the same time, at the middle zone
and lower zone the grains elongated and the size were slightly the same as in Figure
4.2 and Figure 4.3.
In the third layer of 3 layers specimen, the upper zone shows that the grain
were large which is almost the same size with upper zone of 1 layer in Figure 4.1.
Meanwhile, in the middle zone, instead of grain formation, there are sea of delta
ferrite. At lower zone of the third layer shows that there are formation of different
size and orientation of grains and detla ferrite.
Figure 4.9: Upper zone of the 3rd layer in 3 layers WAAM
Figure 4.11: Transition area of 1st and 2nd layer in 5 Layers WAAM
Figure 4.12: Transition area of 2nd and 3rd layer in 5 Layers WAAM
Figure 4.13: Transition area of 3rd and 4th layer in 5 Layers WAAM
Figure 4.14: Transition area of 4th and 5th layer in 5 Layers WAAM
For the first layer of this specimen, it shows that the grain elongated more in
all zone compare to when it is in Figure 4.1, Figure 4.2, Figure 4.3, Figure 4.6,
Figure 4.7 and Figure 4.8. The grain boundary also formed in the upper zone.
Figure 4.15: Upper zone of the 1st layer in 5 Layers WAAM
Meanwhile, for the fifth layer or the top layer of this specimen shows no
massive grain growth as the top layer for 1 layer, Figure 4.1 and 3 layers specimen,
Figure 4.9. The formation of delta ferrite occured at all zones of the fifth layer.
For all specimens, upper zone of the upper layer; Figure 4.1,Figure 4.6 and
Figure 4.21, the weld contain lesser amounts of delta ferrite but the size were bigger
and continous. This happened because the cooling rate on the upper zone of these top
layers is higher compare to other zone [6]. Meanwhile, for other zones, formation of
fine and discontinous delta ferrite. This phenomenon is associated with slower
cooling rate in the zones due to the preheating resulted from prior weld passes [9].
The growth process of the grains occurs after recrystallization and depends on the
temperature, the time and the chemical composition of the steel [5][10].
However, when more layers are weld above it, the microstructure transform
into discontinous delta ferrite. As the temperature reading around 600 celcius for 4th
and 5th layer, the microstructure shows a more stable orientation with discontinious
delta ferrite in all zone of the weld.
5.1 Conclusion
5.2 Recommendations
As there is one and only robot that is available for the robotic welding
process in the lab, any problem or breakdown of the robot can affect the schedule of
the research. Furthermore, the maintenance cost of the robot is very expensive. A
good maintenance scheme will help to ensure the robot in a good condition and
always be ready for the experimental process.
All students of FKM shared one robot to perform robotic welding as there is
only one robot that is available in the faculty. Hence, the faculty should have
structured a well planned schedule for the usage of the robot. A technician also
should always ready to monitor the activity of the student when using the robot to
prevent misusage or unwanted emergency arise that affect the condition of the robot.
REFERENCES