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400112

Effect of Wire Arc Additive Manufacturing Process Parameters on Bead Geometry and Porosity Formation of 5356 Aluminum alloy

Article

Last updated: 07 Jan 2025

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Subjects

-

Tags

Additive manufacturing

Abstract

Wire Arc Additive Manufacturing offers significant potential for producing large, complex aluminum parts with reduced cost and material waste. This study investigates the effects of process parameters, including voltage, scanning speed, and energy density, on the bead geometry and porosity formation of aluminum alloy ER5356 in the WAAM process. A series of 36 single-track aluminum samples were fabricated under varying welding conditions. The results demonstrate that increasing voltage enhances bead width and penetration but reduces bead height and contact angle. Similarly, higher scanning speeds result in smaller bead dimensions. Energy density was found to influence both bead geometry and porosity, with higher energy densities increasing porosity. Through current study the optimal voltage levels used vary between (22-24 V) to contribute into track formation consistently. Additionally, the porosity decreased with higher scanning speed and lower energy density. These findings provide valuable insights into optimizing WAAM parameters for aluminum alloys, reducing defects, and improving material performance for industrial applications.

DOI

10.21608/ijmti.2024.338250.1117

Keywords

Wire Arc Additive Manufacturing, Gas Metal Arc Welding, ER5356 Aluminum Alloy, porosity, bead geometry

Authors

First Name

Eman

Last Name

Shams

MiddleName

-

Affiliation

Mechanical Engineering Department, Faculty of Engineering, Nahda University, New Bani Sweif, Egypt

Email

eman.shams@nub.edu.eg

City

Cairo

Orcid

-

First Name

Marwan

Last Name

Abdelwahed

MiddleName

-

Affiliation

Design and Production Engineering Department, Faculty of Engineering, Ain-Shams University, 11517 Cairo, Egypt

Email

marwan.faisal@eng.asu.edu.eg

City

-

Orcid

-

First Name

Noha

Last Name

Ramadan

MiddleName

-

Affiliation

Design and Production Engineering Department, Faculty of Engineering, Ain-Shams University, 11517 Cairo, Egypt

Email

noha.ramadan@eng.edu.eg

City

-

Orcid

-

First Name

Mohamed

Last Name

Awad

MiddleName

-

Affiliation

Mechatronics Engineering Department, Faculty of Engineering, Ain-Shams University, 11517 Cairo, Egypt

Email

mohammed.awad@eng.asu.edu.eg

City

-

Orcid

-

First Name

Nahed

Last Name

El-Mahallawy

MiddleName

-

Affiliation

Design and Production Engineering Department, Faculty of Engineering, Ain-Shams University, 11517 Cairo, Egypt

Email

nahed_elmahalawy@eng.asu.edu.eg

City

-

Orcid

-

First Name

Mohamed

Last Name

Taha

MiddleName

-

Affiliation

Design and Production Engineering Department, Faculty of Engineering, Ain-Shams University, 11517 Cairo, Egypt

Email

mohamed_taha@eng.asu.edu.eg

City

-

Orcid

-

Volume

4

Article Issue

2

Related Issue

52594

Issue Date

2024-12-01

Receive Date

2024-11-24

Publish Date

2024-12-01

Page Start

39

Page End

45

Online ISSN

2682-4299

Article File

IJMTI_Volume 4_Issue 2_Pages 39-45.pdf

PDF . 968.3kB

Link

https://ijmti.journals.ekb.eg/article_400112.html

Detail API

http://journals.ekb.eg?_action=service&article_code=400112

Order

6

Type

Special issue

Type Code

2,428

Publication Type

Journal

Publication Title

International Journal of Materials Technology and Innovation

Publication Link

https://ijmti.journals.ekb.eg/

MainTitle

Effect of Wire Arc Additive Manufacturing Process Parameters on Bead Geometry and Porosity Formation of 5356 Aluminum alloy

Details

Type

Article

Created At

07 Jan 2025