Effect of electrode materials and process parameters on deposition characteristics during GMAW-AM

ABSTRACT

This experimental investigation introduced the gas metal arc welding-based additive manufacturing to deposit single-layered beads of ER70S–6 and 316 L stainless steel (SS). Different experimental conditions are generated through response surface methodology for illustrating the effect of wire electrode material and deposition parameters on bead characteristics. From parametric analysis, wire feed speed and torch speed are found to be the most controlling factors for bead width, height, deposition area, penetration depth, dilution, and contact angle. Deposition with 316 L SS wire exhibits minimal bead characteristic features than ER70S–6 because of high electrical resistivity that restricts excessive flow of arc current (low thermal energy development) and maintains the molten pool stability. Microstructural transformation from the continuous nature of δ-ferrite into an isolated core-like structure indicates the heat input’s role over grain refinement. X-ray diffraction depicts α-Fe and ϒ-austenite phases (with δ-Fe) in ER70S–6 and 316 L SS deposits.

KEYWORDS:

• Gas
• metal
• Arc
• welding
• additive
• manufacturing
• RSM
• macrostructure
• microstructure
• XRD

Acknowledgments

The authors would like to acknowledge ‘The Institution of Engineers (India) (Project ID: DR2022003)’ for the financial support of this experimental investigation.

Disclosure statement

No potential conflict of interest was reported by the authors.

Additional information

Funding

The work was supported by the The Institution of Engineers (India) [DR2022003].