Influence of waam process parameters on morphology of beads when coating high temperature stainless steels ss309l on low carbon steel plates tran dinh van

International Research Journal of Advanced Engineering and Science ISSN (Online): 2455-9024 Influence of WAAM Process Parameters on Morphology of Beads When Coating High-Temperature Stainless Steels SS309L on Low Carbon Steel Plates Dang Van Thuc1, Dao Van Luu1, Phan Hoang Cuong1, Quyet Tien Ha2, Tran Dinh Van3 Advanced Technology Centre, Le Quy Don Technical University, Ha Noi, Viet Nam Military Industrial College, Vietnam National Research Institute of Mechanical Engineering, Ha Noi, Viet Nam Abstract— Wire-arc additive manufacturing (WAAM) has excellent promise for manufacturing large-sized parts Compared to other metallic additive manufacturing (MAM) technologies, the outstanding advantages of this technology are the high rate of depositing materials, relatively low equipment investment costs, and many materials available in the market However, WAAM is still a new technology and is being studied to gain a comprehensive understanding of industrial applications Recently published works have focused on analyzing the appearance, metallurgical and mechanical characteristics of parts made from different materials Among them, steel is the most studied material because they are commonly used in industry In this paper, a case study on the coating of high-temperature stainless steels on low-carbon steels using the WAAM process is investigated The geometrical parameters of welding beads were analyzed and discussed The reasonable welding parameters were considered for future work while wire dripping problems are associated with excessive heat input A mathematical model was developed and validated for the prediction of the surface of a deposited layer comprised of alternate over-lapping beads of iron and Inconel [6] The results of the research show a better approximation when compared to the previous model described by another research As a kind of metal-based AM technologies, wire arc additive manufacturing (WAAM) uses welding arc as the heat source and a solid wire as the feedstock material This reveals a prospective method for manufacturing metal parts or surfacing clad with medium to large size and medium geometric complexity This technique presents a high material deposition rate up to 10 kg/h and lower costs of equipment investment [7] In the WAAM operations, an arc is created between the consumable wire's tip and the workpiece while being shielded by a gas [8]–[10] Plasma arc welding (PAW), gas tungsten arc welding (GTAW), and gas metal arc welding (GMAW) can all be used as the arc heat source in WAAM operations The deposition rate of GMAW-based AM processes is two to three times higher in terms of productivity than those of GTAW-based and PAW-based AM processes [11] Hence, the GMAW-based AM process is more suited for the manufacture of parts with large dimensions In this study, the effects of welding parameters (voltage, current, and travel speed) on the morphologies and the geometrical parameters of welding beads were considered and discussed Some suitable values of parameters were chosen for cladding application by GMAW-WAAM Keywords— WAAM, coating, stainless steels, 309L I INTRODUCTION Carbon steel is a popular structural material due to its high mechanical strength, low cost and, ease of fabrication However, the resistance to corrosion in harsh working conditions such as in water and high temperature of carbon steel is very low Normally, to fabricate parts working in corrosive environments, austenitic stainless steel (SS) alloy is often used However, the cost of stainless steel is often many times higher than that of carbon steel Especially when the parts have large structural shape, the cost of materials will be expensive Therefore, in order to save material costs, stainless steel alloys were coated on the surface of carbon steel parts such as pressure vessels in nuclear [1], pipelines in the petrochemical industry [2], and industrial desalination [3] Laser source base additive manufacturing (AM) has been widely used in parts surface coating Xue et al [4] studied the effects of Ni25 transitional layer on microstructural evolution and wear properties of laser-clad composite coating on H13 tool steel The average microhardness and wear performance of the composite coating were higher than those of the substrate, which was consistent with industrial application standards In order to study the impact of processing parameters (laser power and travel speed) on metallurgical bonding and microstructures, Bozeman et al [5] clad 309L stainless steel wire onto carbon steel substrates Cracking, stubbing, and delamination flaws are associated with insufficient heat input II MATERIALS AND METHODS A Materials (SS309L) Stainless steels are high-alloy steels that have higher corrosion resistance compared to other steels due to the presence of large amounts of chromium Based on their crystalline structure, they are further divided into ferritic, austenitic, and martensitic steels Grade 309 stainless steel has high corrosion resistance and strength compared to grade 304 stainless steel The chemical compositions of SS309L steel are listed in Table TABLE Chemical compositions of SS400 and SS309L steels (wt.%) Material C Mn Si Cr Ni Mo P S Fe SS400