INVESTIGATION ON MECHANICAL PROPERTIES

OF WIRE ARC ADDITIVE MANUFACTURING

(WAAM) OF 316L STAINLESS STEEL USING FEM
SIMULATION AND EXPERIMENT

AIMAN / KEVAL
WAA M Advance Manufacturing and Technology Excellence Center (AMTEx)
TEAM Faculty of Mechanical Engineering
Universiti Teknologi MARA (UiTM)
WIRE ARC ADDITIVE
MANUFACTURING (WAAM)
• Complex Geometry
and Freedom Design
(layer-by-layer basis)
• Austenitic Stainless
Steel 316L
WELDING PROCESS
(EXPERIMENTAL)
- FIND WELD   1 2 3 4 WITH THE NORMAL AND 2
PARAMETER Current 174 A 172 A 170 A 174 A
MINUTES HOLDING TIMES
- CHECK THE QUALITY
Voltage 19.8 V 19.8 V 19 V 20 V
WELDING BY VISUAL
Power 3.4 kW 3.4kW 3.2kW 3.1.kW

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

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

100% 100% 100% 100%

Gas Argon Argon Argon Argon
WHY FEM-SIMULATION OF WAAM
PRODUCTION PROCESS?

PRODUCTION
PARAMETER
DISTORTION
TEMPERATURE
DISTRUBUTION
RESIDUAL STRESS  FEM-Modell of 3 String10 Layers
 3 Main Parts
(TABLE,PLATE,WELDFILLER)
 Alternating Welding- Direction
DISTORTION

Distortion at the vertical view (Y-direction)

DIFFERENT
TEMPERATURE AT
THE FLOW CURVE
(PLASTIC
DEFORMATION )

Normal High
RESIDUAL STRESS
RESIDUAL STRESS 3S10L 3rd Layers
250
6th Layers

200 9th Layers

Stress Reliability Limit MPa

150

100

50

0
0 5 10 15 20 25

S t r e s s R e lia b ilit y L im it M P a
Width of weld filler (mm)

Base
SIMULATION RESULT
- WITH SUBTRATE AND TABLE
- WITHOUT SUBTRATE AND
Effective Stress at the Base Product

TABLE(NON LONGER 100

80

COOLING RATE) 60
40
20
0
0 5 10 15 20 25
Width of weld filler (mm)
X-RAY DIFFRACTION (XRD)
METHOD

Stress Reliability Limit

RESIDUAL STRESS 3S10L
3500 3237.56

3000
2487.21
2500
2005.01
2000

1500

1000 796.91
540.97
500
197.16
1 2 3 4 5
Nodes [Y VALUE]
String 1 String 2 String 3
0
0.5 1 1.5 2 2.5 3 3.5 4 4.5 [Y VALUE]
5 5.5
Position
-500 [Y VALUE]

3rd Layers 3237.56 540.97 796.91 -1000

Strings
 

6th Layers 197.16 -175.83 -697.78

  3rd Layers (+) Tensile Residual stress
6th Layers
2487.21 2005.01 -311.66 (-) Compressive Residual stress
9th Layers 9th Layers
 
Energy-dispersive X-ray
spectroscopy(EDX)
Bottom
 
CATALOG
 
WIRE 316L
 
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
Middle
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

Top
CrK 18.4 18. 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. 19.2 17.5 16.4 17.5 17
4 6
Average 17.73333333 19.08333333 18.66 17.53333333

Mn 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
K
Average 2.433333333 2.85 2.52 2.383333333
Wire
FeK Balance 68.8 67.9 67.5 66.2 66.6 67.9 65.5 66.7 67 67.6 66.5 62. 67 61.7 58.9 63.8 59.7
7
Average 67.48333333 66.66 62.3

NiK 12.2 12. 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. 9 12 8.6 8.9 9.3
8 8
Average 11.91666667 9.65 9.98 9.933333333
 MECHANICAL
PROPERTIES
MACROSTRUCTURE HARDNESS TEST
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

COMPARISON OF SIZE WELD FILLER ACTUAL AND 1S10L 151.3 1S10L 163.7 1S10L 155.2
SIMULATION

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

2.5 mm      
 
  7.5 mm  
AVERAGE ALL WELD FILLER EXPERIMENTAL
  SIMULATION