Adnan A Ugla | University of Thi-Qar, Iraq (original) (raw)
Papers by Adnan A Ugla
Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, Oct 17, 2016
Tungsten inert gas arc welding–based shaped metal deposition is a novel additive manufacturing te... more Tungsten inert gas arc welding–based shaped metal deposition is a novel additive manufacturing technology which can be used for fabricating solid dense parts by melting a cold wire on a substrate in a layer-by-layer manner via continuous DC arc heat. The shaped metal deposition method would be an alternative way to traditional manufacturing methods, especially for complex featured and large-scale solid parts manufacturing, and it is particularly used for aerospace structural components, manufacturing, and repairing of die/molds and middle-sized dense parts. This article presents the designing, constructing, and controlling of an additive manufacturing system using tungsten inert gas plus wire–based shaped metal deposition method. The aim of this work is to design and develop tungsten inert gas plus wire–based shaped metal deposition system to be used for fabricating different components directly from computer-aided design data with minimum time consumed in programming and less boring task compared to conventional robotic systems. So, this article covers the important design steps from computer-aided design data to the final deposited part. The developed additive system is capable of producing near-net-shaped components of sizes not exceeding 400 mm in three-dimensional directly from computer-aided design drawing. The results showed that the developed system succeeded to produce near-net-shaped parts for various features of SS308LSi components. Additionally, workshop tests have been conducted in order to verify the capability and reliability of the developed additive manufacturing system. The developed system is also capable of reducing the buy-to-fly ratio from 5 to 2 by reducing waste material from 1717 to 268 g for the sample components.
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Journal of Nondestructive Evaluation
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Social Science Research Network, Nov 12, 2020
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Social Science Research Network, 2018
MIG-welding plus cold deposition (SMD) is a technique of relatively new technologies for additive... more MIG-welding plus cold deposition (SMD) is a technique of relatively new technologies for additive manufactured parts, which enables to create components in the form of near shaped parts using the metal inert gas method. The SMD technique is made by depositing a main wire plus cold feed w the experimental setup consists machine to be able to apply the deposition process paths. The current work focused on investigating the effect of deposition deposited wall hardness of the deposited specimens. The controlled input parameters in this work were melting current, traveling speed, and wire feed ratio as a new parameter. The results were analyzed by statistical tech and signal/noise ratio. Confirmatory test had been carried out to achieve the validity of results. The results showed that the wire ratio contributes 49.42% towards the overall variation noticed within removed layer thickne contributes 34.15% of the overall variation noticed within removed layer thickness. Wire feed ratio contributes 59.22% hardness. The traveling speed contributes 38.31% of the overall vari within hardness. The optimal value of hardness is 283.521, whereas layer is 0.5791. From the results, it is clear that the wire feed ratio greatly affects the deposited parts quality, and hence the shaped metal deposition Keywords: Additive manufacturing, shaped metal deposition, double welding, cold wire feed, Taguchi Method, S/N ratio IJMET/index.asp 2438 Al-Nasiriyah, Iraq-64001 welding plus cold-wire feed (CWF) based on 3D-printing D) is a technique of relatively new technologies for additive manufactured parts, which enables to create components in the form of near shaped parts using the metal inert gas method. The SMD technique is made by depositing a main wire plus cold feed wire melted by arc welding heat. In this paper, the experimental setup consists of MIG-welding plus cold wire feed and 3 machine to be able to apply the deposition process paths. The current work focused on investigating the effect of deposition parameters on the wall bead geometry and deposited wall hardness of the deposited specimens. The controlled input parameters in this work were melting current, traveling speed, and wire feed ratio as a new parameter. The results were analyzed by statistical technique, i.e. analysis of variance and signal/noise ratio. Confirmatory test had been carried out to achieve the validity The results showed that the wire ratio contributes 49.42% towards the overall variation noticed within removed layer thickness. The traveling speed contributes 34.15% of the overall variation noticed within removed layer thickness. Wire feed ratio contributes 59.22% towards the overall variation noticed within hardness. The traveling speed contributes 38.31% of the overall vari within hardness. The optimal value of hardness is 283.521, whereas the results, it is clear that the wire feed ratio greatly affects the deposited parts quality, and hence this parameter is considered as a new addition to the shaped metal deposition technique using the 3D-SMD plus a cold wire feed. : Additive manufacturing, shaped metal deposition, double welding, cold wire feed, Taguchi Method, S/N ratio. editor@iaeme.com 259 ET&VType=9&IType=11 WIRE MIG EPOSITION D PRINTED AISI of Mechanical Engineering, College of Engineering, Advanced Manufacturing Technology Research Group, University of Thi-Qar, printing-shaped metal D) is a technique of relatively new technologies for additive manufactured parts, which enables to create components in the form of near-net shaped parts using the metal inert gas method. The SMD technique is made by ire melted by arc welding heat. In this paper, welding plus cold wire feed and 3-axis machine to be able to apply the deposition process paths. The current work focused on ters on the wall bead geometry and deposited wall hardness of the deposited specimens. The controlled input parameters in this work were melting current, traveling speed, and wire feed ratio as a new analysis of variance and signal/noise ratio. Confirmatory test had been carried out to achieve the validity The results showed that the wire ratio contributes 49.42% towards the ss. The traveling speed contributes 34.15% of the overall variation noticed within removed layer thickness. towards the overall variation noticed within hardness. The traveling speed contributes 38.31% of the overall variation noticed within hardness. The optimal value of hardness is 283.521, whereas total removed the results, it is clear that the wire feed ratio greatly affects the new addition to SMD plus a cold wire feed. : Additive manufacturing, shaped metal deposition, double-wire MIG
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Shaped Metal Deposition (SMD) is an innovative manufacturing procedure, its an additive layers ma... more Shaped Metal Deposition (SMD) is an innovative manufacturing procedure, its an additive layers manufacturing technique offers a fast, multipurpose, and cost-effective substitute for the traditional manufacturing techniques, and is ideal for the production of short-runs of parts, mass customization, or a one-off repair solution and used for manufacturing large, expensive metal components with complex geometry in addition to fabricating free structures by construction materials in a layer by layer technique. This paper aims to comprehensively review the most prominent facts that researchers have dealt with in the SMD techniquesespecially those associated with the grain refinement features used in the SMD process. This study intends to review the literature presented on metal deposition processes and its advantages, including SMD process usingWire + Arc Additive Manufacturing (WAAM) which divides intowire + tungsten inert gas (TIG), metal inert gas (MIG), DW-SMD process. This literary ...
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The aim of this work is to investigate the influence of the welding process parameters on the mec... more The aim of this work is to investigate the influence of the welding process parameters on the mechanical and metallographical properties of weldments curried out using TIG welding with pulsed/non pulsed current processes. The cooling state was introduces as an input parameter to investigate the main effects on the structure morphology and thereby the mechanical property. In this work the selected pulse frequency levels were 5-500 Hz in order to show the effect of low and high frequencies on the weldment characteristics of AISI 304L plates using filler metal of ER 308LSi. In this work, three levels four factors Taguchi L9 orthogonal array was used to analyze the ultimate tensile strength and micro-hardness of the welded specimens. Taguchi analysis was performed for the main effects plot to optimize the process parameters. Furthermore, the microstructure evolution has been investigated. The key findings of this work clarified that the pulse frequency has significant effect on the brea...
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Innovative Systems Design and Engineering, 2016
The aim of this work is to investigate the influence of the welding process parameters on the wel... more The aim of this work is to investigate the influence of the welding process parameters on the weld bead geometry, microstructure characteristics, and mechanical properties of weldments curried out using TIG welding with pulsed/non pulsed current processes. The cooling state was introduces as an input parameter to investigate the main effects on the structure morphology and thereby the mechanical property. In this work the selected pulse frequency levels were 5-500 Hz in order to show the effect of low and high frequencies on the weldment characteristics of AISI 304L plates using filler metal of ER 308LSi. In this work, three levels four factors Taguchi L9 orthogonal array was used to analyze the aspect ratio of the welded specimens. Taguchi analysis was performed for the main effects plot to optimize the process parameters. Furthermore, the microstructure evolution has been investigated. Thus key findings of this work clarified that the pulse frequency has significant effect on the ...
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MIG-welding plus cold deposition (SMD) is a technique of relatively new technologies for additive... more MIG-welding plus cold deposition (SMD) is a technique of relatively new technologies for additive manufactured parts, which enables to create components in the form of near shaped parts using the metal inert gas method. The SMD technique is made by depositing a main wire plus cold feed w the experimental setup consists machine to be able to apply the deposition process paths. The current work focused on investigating the effect of deposition deposited wall hardness of the deposited specimens. The controlled input parameters in this work were melting current, traveling speed, and wire feed ratio as a new parameter. The results were analyzed by statistical tech and signal/noise ratio. Confirmatory test had been carried out to achieve the validity of results. The results showed that the wire ratio contributes 49.42% towards the overall variation noticed within removed layer thickne contributes 34.15% of the overall variation noticed within removed layer thickness. Wire feed ratio contr...
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Journal of Physics: Conference Series, 2021
In the turning process, the quality of the working surface depends on the operating parameters. I... more In the turning process, the quality of the working surface depends on the operating parameters. In this work method was used Taguchi to study the effect of operating transactions on the surface quality of the operator (the barrel). In this study four parameters were used which are sample length (L), sample diameter (D), feed rate (F), and cut depth (T). The objective of this work is to improve the quality of the surface of the machine through the control of the main input parameters for the process of turning aluminum and steel materials. It was selected orthogonal group L9 to study the impact of key factors on the variable response, i.e. barreling. The contribution of key factors and their interaction with the optimal level were determined using ANOVA. The results showed that the cutting depth was 0.5 mm and the feeding rate was 0.5 mm/roll yield minimum barreling. In addition, ANOVA results indicated that among four major factors, the specimen diameter and cut depth significantly ...
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Materials Science Forum, 2021
Heat resistant coatings are considered for the external surface Low-Pressure Steam Turbines (LPST... more Heat resistant coatings are considered for the external surface Low-Pressure Steam Turbines (LPST). 410 stainless steel covered with nano heat resistant coatings consists of a heat resistant connecting layer enhanced by nanoparticles. A commercial paint was modified by using 20%wt of (titanium dioxide (TiO2) - aluminum oxide (Al2O3)) with different concentrations range (25,50,75wt% of TiO2) layers. These nano-coatings paints were airbrushed onto the surface of specimens of steam turbine blades. The test rig and experimental apparatus have been fabricated and collected to accomplish the thermal tests. The samples were subjected to heat resistance and a temperature test approximately similar to the steam turbine's operation condition temperature. The test results are used to choose the nano-coating layer with a concentration that ensures a composition's highest protective properties. The test sample with concentration (paint-(75% Al2O3+25% TiO2)) showed the highest thermal pro...
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Al-Qadisiyah Journal for Engineering Sciences, 2020
In this paper, an experimental electrical distribution transformer was studied and a new techniqu... more In this paper, an experimental electrical distribution transformer was studied and a new technique was proposed to improve the performance of a new mixed cooling consisting of pure transformer oil, paraffin wax and nanoparticles. The experiment was carried out on a small transformer that was done by taking a model with dimensions (15 * 10 * 10) cm to facilitate calculations. Paraffin wax absorbs the heat generated in the transformer due to the smelting process that can be used to cool electrical appliances. Nanoparticles have good thermal properties and lead to increased oil insulation to thermal improvements in transformer oil with dispersal of solid nanoparticles and their effects on transformer cooling. Three types of solid nanoparticles were used in this experiment (Al2O3, TiO2, and Sic) with a different volume concentration (1%, 3%, and 5%) and 4% paraffin wax as a certified added percentage for each process. The obtained results showed that when mixing paraffin wax and solid n...
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Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2016
Tungsten inert gas arc welding–based shaped metal deposition is a novel additive manufacturing te... more Tungsten inert gas arc welding–based shaped metal deposition is a novel additive manufacturing technology which can be used for fabricating solid dense parts by melting a cold wire on a substrate in a layer-by-layer manner via continuous DC arc heat. The shaped metal deposition method would be an alternative way to traditional manufacturing methods, especially for complex featured and large-scale solid parts manufacturing, and it is particularly used for aerospace structural components, manufacturing, and repairing of die/molds and middle-sized dense parts. This article presents the designing, constructing, and controlling of an additive manufacturing system using tungsten inert gas plus wire–based shaped metal deposition method. The aim of this work is to design and develop tungsten inert gas plus wire–based shaped metal deposition system to be used for fabricating different components directly from computer-aided design data with minimum time consumed in programming and less borin...
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Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2016
Shaped metal deposition is a relatively new additive layered manufacturing method. It is a novel ... more Shaped metal deposition is a relatively new additive layered manufacturing method. It is a novel technique to build net-shaped or near-net-shaped metal components in a layer-by-layer manner via applying metal wire and selection of a heat source such as laser beam, electron beam, or electric arc. It is a manufacturing method used for production of complex featured and large-scaled parts, especially in aerospace and metal-die industries. This method can lower the cost of fabricated parts by reducing further machining and finishing processes and shortening lead time. This article presents a comprehensive literature review on shaped metal deposition, and it mainly aims to highlight some of the areas which were reported by the researchers in this field to give an extensive overview of shaped metal deposition processes, classification of its methods, and their applications. The presented literature review covers extensive details on microstructure, mechanical properties, and residual stre...
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Shaped Metal Deposition (SMD) in additive layered manufacturing technique is a promising alternat... more Shaped Metal Deposition (SMD) in additive layered manufacturing technique is a promising alternative to traditional manufacturing used for manufacturing large, expensive metal components with complex geometry in addition to producing free structures by building materials in a layer by layer technique. The present paper is a comprehensive review of the literature and the latest rapid manufacturing technologies of the SMD technique. The aim of this paper is to comprehensively review the most prominent facts that researchers have dealt with in the SMD techniques especially those associated with the cold wire feed. The intent of this study is to review the literature presented on metal deposition processes and their classifications, including SMD process using Wire <strong>+</strong> Arc Additive Manufacturing (WAAM) which divides into wire + tungsten inert gas (TIG), metal inert gas (MIG), or plasma. This literary research presented covers extensive details on bead geometry...
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Journal of Materials Engineering and Performance
Shaped metal deposition (SMD) using metal inert gas welding plus externally cold wire is a relati... more Shaped metal deposition (SMD) using metal inert gas welding plus externally cold wire is a relatively new technology of additive manufacturing, which fabricates near-net shaped parts. It is performed by depositing a main wire plus a cold feed wire melted by the electric arc heat. In the present work, a new experimental setup was developed, which consists of a MIG-welding source and an external cold wire feed unit plus a 3axis machine. The main intent of the current paper is to investigate the microstructural and mechanical properties of austenitic stainless steel grade 309L deposited parts. The result showed that the value of the wire feed ratio (WR) plays an important role in both microstructure and mechanical properties. The microstructure mainly consists of two phases ferrite and austenite as predominant phases throughout the parts. Widmansttãten austenite structure that is denoted as (W) this appears in the white region, and Vermicular delta ferrite (V) appears as the dark-etching phase. The tensile test results showed the UTS value increased by 17.36% in the longitudinal direction when using cold feeding, while it increased by 4.39% in the vertical direction. The hardness test results showed that the hardness value increased by 36.23% when using cold feeding. Also, cold wire feeding reduces interpass temperature into the workpiece by 10%. Keywords additive manufacturing, cold wire feeding, mechanical properties of AM, microstructure, MIG-welding This invited article is part of a special topical focus in theJournal of Materials Engineering and Performance on Additive Manufacturing.
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Arabian Journal for Science and Engineering
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International Journal of Mechanical Engineering and Technology, 2018
MIG-welding plus cold deposition (SMD) is a technique of relatively new technologies for additive... more MIG-welding plus cold deposition (SMD) is a technique of relatively new technologies for additive manufactured parts, which enables to create components in the form of near shaped parts using the metal inert gas method. The SMD technique is made by depositing a main wire plus cold feed w the experimental setup consists machine to be able to apply the deposition process paths. The current work focused on investigating the effect of deposition deposited wall hardness of the deposited specimens. The controlled input parameters in this work were melting current, traveling speed, and wire feed ratio as a new parameter. The results were analyzed by statistical tech and signal/noise ratio. Confirmatory test had been carried out to achieve the validity of results. The results showed that the wire ratio contributes 49.42% towards the overall variation noticed within removed layer thickne contributes 34.15% of the overall variation noticed within removed layer thickness. Wire feed ratio contributes 59.22% hardness. The traveling speed contributes 38.31% of the overall vari within hardness. The optimal value of hardness is 283.521, whereas layer is 0.5791. From the results, it is clear that the wire feed ratio greatly affects the deposited parts quality, and hence the shaped metal deposition Keywords: Additive manufacturing, shaped metal deposition, double welding, cold wire feed, Taguchi Method, S/N ratio IJMET/index.asp 2438 Al-Nasiriyah, Iraq-64001 welding plus cold-wire feed (CWF) based on 3D-printing D) is a technique of relatively new technologies for additive manufactured parts, which enables to create components in the form of near shaped parts using the metal inert gas method. The SMD technique is made by depositing a main wire plus cold feed wire melted by arc welding heat. In this paper, the experimental setup consists of MIG-welding plus cold wire feed and 3 machine to be able to apply the deposition process paths. The current work focused on investigating the effect of deposition parameters on the wall bead geometry and deposited wall hardness of the deposited specimens. The controlled input parameters in this work were melting current, traveling speed, and wire feed ratio as a new parameter. The results were analyzed by statistical technique, i.e. analysis of variance and signal/noise ratio. Confirmatory test had been carried out to achieve the validity The results showed that the wire ratio contributes 49.42% towards the overall variation noticed within removed layer thickness. The traveling speed contributes 34.15% of the overall variation noticed within removed layer thickness. Wire feed ratio contributes 59.22% towards the overall variation noticed within hardness. The traveling speed contributes 38.31% of the overall vari within hardness. The optimal value of hardness is 283.521, whereas the results, it is clear that the wire feed ratio greatly affects the deposited parts quality, and hence this parameter is considered as a new addition to the shaped metal deposition technique using the 3D-SMD plus a cold wire feed. : Additive manufacturing, shaped metal deposition, double welding, cold wire feed, Taguchi Method, S/N ratio. editor@iaeme.com 259 ET&VType=9&IType=11 WIRE MIG EPOSITION D PRINTED AISI of Mechanical Engineering, College of Engineering, Advanced Manufacturing Technology Research Group, University of Thi-Qar, printing-shaped metal D) is a technique of relatively new technologies for additive manufactured parts, which enables to create components in the form of near-net shaped parts using the metal inert gas method. The SMD technique is made by ire melted by arc welding heat. In this paper, welding plus cold wire feed and 3-axis machine to be able to apply the deposition process paths. The current work focused on ters on the wall bead geometry and deposited wall hardness of the deposited specimens. The controlled input parameters in this work were melting current, traveling speed, and wire feed ratio as a new analysis of variance and signal/noise ratio. Confirmatory test had been carried out to achieve the validity The results showed that the wire ratio contributes 49.42% towards the ss. The traveling speed contributes 34.15% of the overall variation noticed within removed layer thickness. towards the overall variation noticed within hardness. The traveling speed contributes 38.31% of the overall variation noticed within hardness. The optimal value of hardness is 283.521, whereas total removed the results, it is clear that the wire feed ratio greatly affects the new addition to SMD plus a cold wire feed. : Additive manufacturing, shaped metal deposition, double-wire MIG
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IOP Conference Series: Materials Science and Engineering
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University of Thi-Qar Journal for Engineering Sciences
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Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, Oct 17, 2016
Tungsten inert gas arc welding–based shaped metal deposition is a novel additive manufacturing te... more Tungsten inert gas arc welding–based shaped metal deposition is a novel additive manufacturing technology which can be used for fabricating solid dense parts by melting a cold wire on a substrate in a layer-by-layer manner via continuous DC arc heat. The shaped metal deposition method would be an alternative way to traditional manufacturing methods, especially for complex featured and large-scale solid parts manufacturing, and it is particularly used for aerospace structural components, manufacturing, and repairing of die/molds and middle-sized dense parts. This article presents the designing, constructing, and controlling of an additive manufacturing system using tungsten inert gas plus wire–based shaped metal deposition method. The aim of this work is to design and develop tungsten inert gas plus wire–based shaped metal deposition system to be used for fabricating different components directly from computer-aided design data with minimum time consumed in programming and less boring task compared to conventional robotic systems. So, this article covers the important design steps from computer-aided design data to the final deposited part. The developed additive system is capable of producing near-net-shaped components of sizes not exceeding 400 mm in three-dimensional directly from computer-aided design drawing. The results showed that the developed system succeeded to produce near-net-shaped parts for various features of SS308LSi components. Additionally, workshop tests have been conducted in order to verify the capability and reliability of the developed additive manufacturing system. The developed system is also capable of reducing the buy-to-fly ratio from 5 to 2 by reducing waste material from 1717 to 268 g for the sample components.
Bookmarks Related papers MentionsView impact
Journal of Nondestructive Evaluation
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Social Science Research Network, Nov 12, 2020
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Social Science Research Network, 2018
MIG-welding plus cold deposition (SMD) is a technique of relatively new technologies for additive... more MIG-welding plus cold deposition (SMD) is a technique of relatively new technologies for additive manufactured parts, which enables to create components in the form of near shaped parts using the metal inert gas method. The SMD technique is made by depositing a main wire plus cold feed w the experimental setup consists machine to be able to apply the deposition process paths. The current work focused on investigating the effect of deposition deposited wall hardness of the deposited specimens. The controlled input parameters in this work were melting current, traveling speed, and wire feed ratio as a new parameter. The results were analyzed by statistical tech and signal/noise ratio. Confirmatory test had been carried out to achieve the validity of results. The results showed that the wire ratio contributes 49.42% towards the overall variation noticed within removed layer thickne contributes 34.15% of the overall variation noticed within removed layer thickness. Wire feed ratio contributes 59.22% hardness. The traveling speed contributes 38.31% of the overall vari within hardness. The optimal value of hardness is 283.521, whereas layer is 0.5791. From the results, it is clear that the wire feed ratio greatly affects the deposited parts quality, and hence the shaped metal deposition Keywords: Additive manufacturing, shaped metal deposition, double welding, cold wire feed, Taguchi Method, S/N ratio IJMET/index.asp 2438 Al-Nasiriyah, Iraq-64001 welding plus cold-wire feed (CWF) based on 3D-printing D) is a technique of relatively new technologies for additive manufactured parts, which enables to create components in the form of near shaped parts using the metal inert gas method. The SMD technique is made by depositing a main wire plus cold feed wire melted by arc welding heat. In this paper, the experimental setup consists of MIG-welding plus cold wire feed and 3 machine to be able to apply the deposition process paths. The current work focused on investigating the effect of deposition parameters on the wall bead geometry and deposited wall hardness of the deposited specimens. The controlled input parameters in this work were melting current, traveling speed, and wire feed ratio as a new parameter. The results were analyzed by statistical technique, i.e. analysis of variance and signal/noise ratio. Confirmatory test had been carried out to achieve the validity The results showed that the wire ratio contributes 49.42% towards the overall variation noticed within removed layer thickness. The traveling speed contributes 34.15% of the overall variation noticed within removed layer thickness. Wire feed ratio contributes 59.22% towards the overall variation noticed within hardness. The traveling speed contributes 38.31% of the overall vari within hardness. The optimal value of hardness is 283.521, whereas the results, it is clear that the wire feed ratio greatly affects the deposited parts quality, and hence this parameter is considered as a new addition to the shaped metal deposition technique using the 3D-SMD plus a cold wire feed. : Additive manufacturing, shaped metal deposition, double welding, cold wire feed, Taguchi Method, S/N ratio. editor@iaeme.com 259 ET&VType=9&IType=11 WIRE MIG EPOSITION D PRINTED AISI of Mechanical Engineering, College of Engineering, Advanced Manufacturing Technology Research Group, University of Thi-Qar, printing-shaped metal D) is a technique of relatively new technologies for additive manufactured parts, which enables to create components in the form of near-net shaped parts using the metal inert gas method. The SMD technique is made by ire melted by arc welding heat. In this paper, welding plus cold wire feed and 3-axis machine to be able to apply the deposition process paths. The current work focused on ters on the wall bead geometry and deposited wall hardness of the deposited specimens. The controlled input parameters in this work were melting current, traveling speed, and wire feed ratio as a new analysis of variance and signal/noise ratio. Confirmatory test had been carried out to achieve the validity The results showed that the wire ratio contributes 49.42% towards the ss. The traveling speed contributes 34.15% of the overall variation noticed within removed layer thickness. towards the overall variation noticed within hardness. The traveling speed contributes 38.31% of the overall variation noticed within hardness. The optimal value of hardness is 283.521, whereas total removed the results, it is clear that the wire feed ratio greatly affects the new addition to SMD plus a cold wire feed. : Additive manufacturing, shaped metal deposition, double-wire MIG
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Shaped Metal Deposition (SMD) is an innovative manufacturing procedure, its an additive layers ma... more Shaped Metal Deposition (SMD) is an innovative manufacturing procedure, its an additive layers manufacturing technique offers a fast, multipurpose, and cost-effective substitute for the traditional manufacturing techniques, and is ideal for the production of short-runs of parts, mass customization, or a one-off repair solution and used for manufacturing large, expensive metal components with complex geometry in addition to fabricating free structures by construction materials in a layer by layer technique. This paper aims to comprehensively review the most prominent facts that researchers have dealt with in the SMD techniquesespecially those associated with the grain refinement features used in the SMD process. This study intends to review the literature presented on metal deposition processes and its advantages, including SMD process usingWire + Arc Additive Manufacturing (WAAM) which divides intowire + tungsten inert gas (TIG), metal inert gas (MIG), DW-SMD process. This literary ...
Bookmarks Related papers MentionsView impact
The aim of this work is to investigate the influence of the welding process parameters on the mec... more The aim of this work is to investigate the influence of the welding process parameters on the mechanical and metallographical properties of weldments curried out using TIG welding with pulsed/non pulsed current processes. The cooling state was introduces as an input parameter to investigate the main effects on the structure morphology and thereby the mechanical property. In this work the selected pulse frequency levels were 5-500 Hz in order to show the effect of low and high frequencies on the weldment characteristics of AISI 304L plates using filler metal of ER 308LSi. In this work, three levels four factors Taguchi L9 orthogonal array was used to analyze the ultimate tensile strength and micro-hardness of the welded specimens. Taguchi analysis was performed for the main effects plot to optimize the process parameters. Furthermore, the microstructure evolution has been investigated. The key findings of this work clarified that the pulse frequency has significant effect on the brea...
Bookmarks Related papers MentionsView impact
Innovative Systems Design and Engineering, 2016
The aim of this work is to investigate the influence of the welding process parameters on the wel... more The aim of this work is to investigate the influence of the welding process parameters on the weld bead geometry, microstructure characteristics, and mechanical properties of weldments curried out using TIG welding with pulsed/non pulsed current processes. The cooling state was introduces as an input parameter to investigate the main effects on the structure morphology and thereby the mechanical property. In this work the selected pulse frequency levels were 5-500 Hz in order to show the effect of low and high frequencies on the weldment characteristics of AISI 304L plates using filler metal of ER 308LSi. In this work, three levels four factors Taguchi L9 orthogonal array was used to analyze the aspect ratio of the welded specimens. Taguchi analysis was performed for the main effects plot to optimize the process parameters. Furthermore, the microstructure evolution has been investigated. Thus key findings of this work clarified that the pulse frequency has significant effect on the ...
Bookmarks Related papers MentionsView impact
MIG-welding plus cold deposition (SMD) is a technique of relatively new technologies for additive... more MIG-welding plus cold deposition (SMD) is a technique of relatively new technologies for additive manufactured parts, which enables to create components in the form of near shaped parts using the metal inert gas method. The SMD technique is made by depositing a main wire plus cold feed w the experimental setup consists machine to be able to apply the deposition process paths. The current work focused on investigating the effect of deposition deposited wall hardness of the deposited specimens. The controlled input parameters in this work were melting current, traveling speed, and wire feed ratio as a new parameter. The results were analyzed by statistical tech and signal/noise ratio. Confirmatory test had been carried out to achieve the validity of results. The results showed that the wire ratio contributes 49.42% towards the overall variation noticed within removed layer thickne contributes 34.15% of the overall variation noticed within removed layer thickness. Wire feed ratio contr...
Bookmarks Related papers MentionsView impact
Journal of Physics: Conference Series, 2021
In the turning process, the quality of the working surface depends on the operating parameters. I... more In the turning process, the quality of the working surface depends on the operating parameters. In this work method was used Taguchi to study the effect of operating transactions on the surface quality of the operator (the barrel). In this study four parameters were used which are sample length (L), sample diameter (D), feed rate (F), and cut depth (T). The objective of this work is to improve the quality of the surface of the machine through the control of the main input parameters for the process of turning aluminum and steel materials. It was selected orthogonal group L9 to study the impact of key factors on the variable response, i.e. barreling. The contribution of key factors and their interaction with the optimal level were determined using ANOVA. The results showed that the cutting depth was 0.5 mm and the feeding rate was 0.5 mm/roll yield minimum barreling. In addition, ANOVA results indicated that among four major factors, the specimen diameter and cut depth significantly ...
Bookmarks Related papers MentionsView impact
Bookmarks Related papers MentionsView impact
Materials Science Forum, 2021
Heat resistant coatings are considered for the external surface Low-Pressure Steam Turbines (LPST... more Heat resistant coatings are considered for the external surface Low-Pressure Steam Turbines (LPST). 410 stainless steel covered with nano heat resistant coatings consists of a heat resistant connecting layer enhanced by nanoparticles. A commercial paint was modified by using 20%wt of (titanium dioxide (TiO2) - aluminum oxide (Al2O3)) with different concentrations range (25,50,75wt% of TiO2) layers. These nano-coatings paints were airbrushed onto the surface of specimens of steam turbine blades. The test rig and experimental apparatus have been fabricated and collected to accomplish the thermal tests. The samples were subjected to heat resistance and a temperature test approximately similar to the steam turbine's operation condition temperature. The test results are used to choose the nano-coating layer with a concentration that ensures a composition's highest protective properties. The test sample with concentration (paint-(75% Al2O3+25% TiO2)) showed the highest thermal pro...
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Al-Qadisiyah Journal for Engineering Sciences, 2020
In this paper, an experimental electrical distribution transformer was studied and a new techniqu... more In this paper, an experimental electrical distribution transformer was studied and a new technique was proposed to improve the performance of a new mixed cooling consisting of pure transformer oil, paraffin wax and nanoparticles. The experiment was carried out on a small transformer that was done by taking a model with dimensions (15 * 10 * 10) cm to facilitate calculations. Paraffin wax absorbs the heat generated in the transformer due to the smelting process that can be used to cool electrical appliances. Nanoparticles have good thermal properties and lead to increased oil insulation to thermal improvements in transformer oil with dispersal of solid nanoparticles and their effects on transformer cooling. Three types of solid nanoparticles were used in this experiment (Al2O3, TiO2, and Sic) with a different volume concentration (1%, 3%, and 5%) and 4% paraffin wax as a certified added percentage for each process. The obtained results showed that when mixing paraffin wax and solid n...
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Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2016
Tungsten inert gas arc welding–based shaped metal deposition is a novel additive manufacturing te... more Tungsten inert gas arc welding–based shaped metal deposition is a novel additive manufacturing technology which can be used for fabricating solid dense parts by melting a cold wire on a substrate in a layer-by-layer manner via continuous DC arc heat. The shaped metal deposition method would be an alternative way to traditional manufacturing methods, especially for complex featured and large-scale solid parts manufacturing, and it is particularly used for aerospace structural components, manufacturing, and repairing of die/molds and middle-sized dense parts. This article presents the designing, constructing, and controlling of an additive manufacturing system using tungsten inert gas plus wire–based shaped metal deposition method. The aim of this work is to design and develop tungsten inert gas plus wire–based shaped metal deposition system to be used for fabricating different components directly from computer-aided design data with minimum time consumed in programming and less borin...
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Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2016
Shaped metal deposition is a relatively new additive layered manufacturing method. It is a novel ... more Shaped metal deposition is a relatively new additive layered manufacturing method. It is a novel technique to build net-shaped or near-net-shaped metal components in a layer-by-layer manner via applying metal wire and selection of a heat source such as laser beam, electron beam, or electric arc. It is a manufacturing method used for production of complex featured and large-scaled parts, especially in aerospace and metal-die industries. This method can lower the cost of fabricated parts by reducing further machining and finishing processes and shortening lead time. This article presents a comprehensive literature review on shaped metal deposition, and it mainly aims to highlight some of the areas which were reported by the researchers in this field to give an extensive overview of shaped metal deposition processes, classification of its methods, and their applications. The presented literature review covers extensive details on microstructure, mechanical properties, and residual stre...
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Shaped Metal Deposition (SMD) in additive layered manufacturing technique is a promising alternat... more Shaped Metal Deposition (SMD) in additive layered manufacturing technique is a promising alternative to traditional manufacturing used for manufacturing large, expensive metal components with complex geometry in addition to producing free structures by building materials in a layer by layer technique. The present paper is a comprehensive review of the literature and the latest rapid manufacturing technologies of the SMD technique. The aim of this paper is to comprehensively review the most prominent facts that researchers have dealt with in the SMD techniques especially those associated with the cold wire feed. The intent of this study is to review the literature presented on metal deposition processes and their classifications, including SMD process using Wire <strong>+</strong> Arc Additive Manufacturing (WAAM) which divides into wire + tungsten inert gas (TIG), metal inert gas (MIG), or plasma. This literary research presented covers extensive details on bead geometry...
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Journal of Materials Engineering and Performance
Shaped metal deposition (SMD) using metal inert gas welding plus externally cold wire is a relati... more Shaped metal deposition (SMD) using metal inert gas welding plus externally cold wire is a relatively new technology of additive manufacturing, which fabricates near-net shaped parts. It is performed by depositing a main wire plus a cold feed wire melted by the electric arc heat. In the present work, a new experimental setup was developed, which consists of a MIG-welding source and an external cold wire feed unit plus a 3axis machine. The main intent of the current paper is to investigate the microstructural and mechanical properties of austenitic stainless steel grade 309L deposited parts. The result showed that the value of the wire feed ratio (WR) plays an important role in both microstructure and mechanical properties. The microstructure mainly consists of two phases ferrite and austenite as predominant phases throughout the parts. Widmansttãten austenite structure that is denoted as (W) this appears in the white region, and Vermicular delta ferrite (V) appears as the dark-etching phase. The tensile test results showed the UTS value increased by 17.36% in the longitudinal direction when using cold feeding, while it increased by 4.39% in the vertical direction. The hardness test results showed that the hardness value increased by 36.23% when using cold feeding. Also, cold wire feeding reduces interpass temperature into the workpiece by 10%. Keywords additive manufacturing, cold wire feeding, mechanical properties of AM, microstructure, MIG-welding This invited article is part of a special topical focus in theJournal of Materials Engineering and Performance on Additive Manufacturing.
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Arabian Journal for Science and Engineering
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International Journal of Mechanical Engineering and Technology, 2018
MIG-welding plus cold deposition (SMD) is a technique of relatively new technologies for additive... more MIG-welding plus cold deposition (SMD) is a technique of relatively new technologies for additive manufactured parts, which enables to create components in the form of near shaped parts using the metal inert gas method. The SMD technique is made by depositing a main wire plus cold feed w the experimental setup consists machine to be able to apply the deposition process paths. The current work focused on investigating the effect of deposition deposited wall hardness of the deposited specimens. The controlled input parameters in this work were melting current, traveling speed, and wire feed ratio as a new parameter. The results were analyzed by statistical tech and signal/noise ratio. Confirmatory test had been carried out to achieve the validity of results. The results showed that the wire ratio contributes 49.42% towards the overall variation noticed within removed layer thickne contributes 34.15% of the overall variation noticed within removed layer thickness. Wire feed ratio contributes 59.22% hardness. The traveling speed contributes 38.31% of the overall vari within hardness. The optimal value of hardness is 283.521, whereas layer is 0.5791. From the results, it is clear that the wire feed ratio greatly affects the deposited parts quality, and hence the shaped metal deposition Keywords: Additive manufacturing, shaped metal deposition, double welding, cold wire feed, Taguchi Method, S/N ratio IJMET/index.asp 2438 Al-Nasiriyah, Iraq-64001 welding plus cold-wire feed (CWF) based on 3D-printing D) is a technique of relatively new technologies for additive manufactured parts, which enables to create components in the form of near shaped parts using the metal inert gas method. The SMD technique is made by depositing a main wire plus cold feed wire melted by arc welding heat. In this paper, the experimental setup consists of MIG-welding plus cold wire feed and 3 machine to be able to apply the deposition process paths. The current work focused on investigating the effect of deposition parameters on the wall bead geometry and deposited wall hardness of the deposited specimens. The controlled input parameters in this work were melting current, traveling speed, and wire feed ratio as a new parameter. The results were analyzed by statistical technique, i.e. analysis of variance and signal/noise ratio. Confirmatory test had been carried out to achieve the validity The results showed that the wire ratio contributes 49.42% towards the overall variation noticed within removed layer thickness. The traveling speed contributes 34.15% of the overall variation noticed within removed layer thickness. Wire feed ratio contributes 59.22% towards the overall variation noticed within hardness. The traveling speed contributes 38.31% of the overall vari within hardness. The optimal value of hardness is 283.521, whereas the results, it is clear that the wire feed ratio greatly affects the deposited parts quality, and hence this parameter is considered as a new addition to the shaped metal deposition technique using the 3D-SMD plus a cold wire feed. : Additive manufacturing, shaped metal deposition, double welding, cold wire feed, Taguchi Method, S/N ratio. editor@iaeme.com 259 ET&VType=9&IType=11 WIRE MIG EPOSITION D PRINTED AISI of Mechanical Engineering, College of Engineering, Advanced Manufacturing Technology Research Group, University of Thi-Qar, printing-shaped metal D) is a technique of relatively new technologies for additive manufactured parts, which enables to create components in the form of near-net shaped parts using the metal inert gas method. The SMD technique is made by ire melted by arc welding heat. In this paper, welding plus cold wire feed and 3-axis machine to be able to apply the deposition process paths. The current work focused on ters on the wall bead geometry and deposited wall hardness of the deposited specimens. The controlled input parameters in this work were melting current, traveling speed, and wire feed ratio as a new analysis of variance and signal/noise ratio. Confirmatory test had been carried out to achieve the validity The results showed that the wire ratio contributes 49.42% towards the ss. The traveling speed contributes 34.15% of the overall variation noticed within removed layer thickness. towards the overall variation noticed within hardness. The traveling speed contributes 38.31% of the overall variation noticed within hardness. The optimal value of hardness is 283.521, whereas total removed the results, it is clear that the wire feed ratio greatly affects the new addition to SMD plus a cold wire feed. : Additive manufacturing, shaped metal deposition, double-wire MIG
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IOP Conference Series: Materials Science and Engineering
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University of Thi-Qar Journal for Engineering Sciences
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