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Journals / Politeknik Dergisi / 2026 / Cilt: 27 Sayı: 5

Comparative Process Parameter Optimization For Wire Arc Additive Manufacturing (WAAM) of E120C-GH4 Metal Cored and ER120S-G Solid Wire

E120C-GH4 METAL ÖZLÜ VE ER120S-G MASİF TELİN TEL ARK EKLEMELİ İMALATI (WAAM) İÇİN KARŞILAŞTIRMALI PROSES PARAMETRE OPTİMİZASYONU

Mustafa Harman(Çankırı Karatekin üniversitesi)0000-0001-6045-0570
Cemil Çetinkaya(GAZI UNIVERSITY, FACULTY OF TECHNOLOGY)0000-0002-0298-1143
Oğuzhan Yılmaz(GAZI UNIVERSITY, FACULTY OF ENGINEERING-ARCHITECTURE)0000-0002-2641-2324
Nevzat Bol(Intecro Robotik A.Ş)0000-0001-6700-7707
Pages
2013–2028
Publication Date
2024-10-02
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AI Summary & Key Takeaways

AI Insight
⚡ TL;DR(Too Long; Didn't Read)

Considering the economy and time, the result shows that metal-cored wire will be much preferable for the WAAM industry because metal-cored wire has 43% less production time and 74% higher metal deposition rate than solid wire.

📌 3 Key Takeaways

🎯
Objective & Hypothesis:Wire arc additive manufacturing (WAAM) method is a metal additive manufacturing method that allows the production of large and medium complexity parts layer by layer by considering the part-specific CAD model.
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Key Findings & Data:Process parameters were optimized to achieve minimum heat input, less production time, and higher metal deposition rate and bead geometry.
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Conclusion & Impact:Considering the economy and time, the result shows that metal-cored wire will be much preferable for the WAAM industry because metal-cored wire has 43% less production time and 74% higher metal deposition rate than solid wire.
🔬Design:Modeling & Simulation
📍Scope:Comprehensive Sample
⚙️Variables:Metal özlü tel · Taguchi metodu · zırh çeliği

Abstract

Wire arc additive manufacturing (WAAM) method is a metal additive manufacturing method that allows the production of large and medium complexity parts layer by layer by considering the part-specific CAD model. Process parameters were optimized to achieve minimum heat input, less production time, and higher metal deposition rate and bead geometry. E120C-GH4 metal-cored seamless high-strength wire with a diameter of 1.2 mm and an ER120S-G solid wire of the same diameter were used at different wire feeding speeds with heat input (low, medium, high). Single and double layer 18 beads were deposited with each of these wires. Samples were prepared for macro section examination and macro hardness measurement processes. Samples with similar deposition volumes were compared in terms of bead geometry, microhardness, penetration depth, deposition time, and the metal deposition rate at the equal heat input. With the aid of the Taguchi method and the samples were subjected to multiple regression analyses. So, the analyses and real experiments allowed comparative experimental studies. Considering the economy and time, the result shows that metal-cored wire will be much preferable for the WAAM industry because metal-cored wire has 43% less production time and 74% higher metal deposition rate than solid wire.

Özet

Tel ark eklemeli imalat (WAAM) yöntemi, parçaya özel CAD modeli dikkate alınarak büyük ve orta karmaşıklıktaki parçaların katman katman üretilmesine olanak sağlayan bir metal eklemeli imalat yöntemidir. Proses parametreleri, minimum ısı girdisi, daha az üretim süresi, daha yüksek metal biriktirme hızı ve duvar geometrisi elde etmek üzere optimize edildi. 1,2 mm çapında E120C-GH4 metal özlü dikişsiz yüksek mukavemetli tel ve aynı çapta ER120S-G masif tel, (düşük, orta, yüksek) ısı girdili farklı tel besleme hızlarında kullanıldı. Bu tellerin her birine tek ve çift katmanlı 18 tane duvar biriktirildi. Makro kesit incelemesi ve makro sertlik ölçümü işlemleri için numuneler hazırlandı. Benzer biriktirme hacimlerine sahip numuneler duvar geometrisi, mikrosertlik, penetrasyon derinliği, biriktirme süresi ve eşit ısı girdisinde metal biriktirme hızı açısından karşılaştırıldı. Taguchi yöntemi yardımıyla örnekler çoklu regresyon analizine tabi tutuldu. Böylece analizler ve gerçek deneyler karşılaştırmalı deneysel çalışmalara olanak sağladı. Sonuç, ekonomi ve zaman dikkate alındığında, metal özlü telin WAAM endüstrisi için daha çok tercih edileceğini göstermektedir çünkü metal özlü tel, masif telden %43 daha az üretim süresine ve %74 daha yüksek metal biriktirme oranına sahiptir.

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Cite This Article

Harman, M., Çetinkaya, C., Yılmaz, O., Bol, N. (2024). Comparative Process Parameter Optimization For Wire Arc Additive Manufacturing (WAAM) of E120C-GH4 Metal Cored and ER120S-G Solid Wire. Politeknik Dergisi, Cilt: 27 Sayı: 5, 2013–2028. https://doi.org/10.2339/politeknik.1478172

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