Evaluation of Additive Manufacturing Parts Machinability using Automated GMAW ER70S-6 with Nodular Cast Iron

Augusto Dttmann,Jefferson De Oliveira Gomes

doi:10.24840/2183-6493_007.002_0011

Augusto Dttmann, Jefferson De Oliveira Gomes

Open Access

https://doi.org/10.24840/2183-6493_007.002_0011

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Abstract

Through additive manufacturing is possible to obtain products with few material waste, low production time and great flexibility in geometry. In recent years, the application of arc welding processes has been studied as additive manufacturing techniques for metals. When compared to laser welding processes, they have low equipment cost, high deposition rate, however a low surface quality. This work proposes to study the machinability of additive manufacturing parts using automated GMAW. The deposition was carried out using a robotic arm, using ER70S-6' wire with a substrate of nodular cast iron. Two deposition strategies were carried out, one alternating the passes directions and the other one depositing in the same direction. The machining process used was milling in a three axis machining center. The deposition strategy had an influence on the parts surface finish after machining, as well as on the tool life.

Highlights

Additive manufacturing (AM) is the production process that consists of layer-by-layer deposition (Jiménez et al 2019; Zhu et al 2020)
This process is known as 3D printing, it allows the production of complex geometries and decreases the production cost and the production cycle time, mainly for small batches (Zhu et al 2020)
The most common deposition processes with metals are laser beam melting (LBM), electron beam melting (EBM), and laser metal deposition (LMD), all generally based on metal powders as feedstock (Herzog et al 2016)

Summary

Introduction

Additive manufacturing (AM) is the production process that consists of layer-by-layer deposition (Jiménez et al 2019; Zhu et al 2020). AM processes using powder as feedstock provide parts with a good surface finish and allows to produce parts with more complex geometries (da Silva et al 2020), the costs are high and the production time for larger dimensions is very long (DebRoy et al 2018). Evaluation of Additive Manufacturing Parts Machinability using Automated GMAW ER70S-6 with Nodular Cast Iron Augusto Dttmann, Jefferson de Oliveira Gomes. These processes are based on welding with gas protection as tungsten arc (GTA) and the variants of gas metal arc (GMA). The deposition was carried out using a robotic arm, using ER70S-6' wire with a substrate of Nodular Cast Iron

Welding deposition

Results and Discussion

Roughness