Evaluation of the Processing Parameters Influence on the Additive Manufacturing of VP50IM Steel by PCGTAW

Toaldo, Paulo Henrique; Ferreira, Arthur Soares Fernandes; Verastégui, Roger Navarro; Pukasiewicz, Anderson Geraldo Marenda

doi:10.1590/0104-9224/SI29.01

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ORIGINAL PAPER • Soldag. insp. 29 • 2024 • https://doi.org/10.1590/0104-9224/SI29.01 copy

Evaluation of the Processing Parameters Influence on the Additive Manufacturing of VP50IM Steel by PCGTAW

Avaliação da Influência dos Parâmetros de Processamento na Manufatura Aditiva do Aço VP50IM por PCGTAW

Authorship SCIMAGO INSTITUTIONS RANKINGS

Abstract

The wire arc additive manufacturing process or WAAM (Wire Additive Arc Welding) is recognized as a process able of making pieces of high geometric complexity, with mechanical properties comparable to those of the cast material. However, there are significant challenges associated with WAAM, such as undesirable microstructures and mechanical properties, high residual stresses and geometric distortion. This study aims to contribute to the selection of deposition parameters for VP50IM steel using WAAM via pulsed TIG (Tungsten Inert Gas) and characterization of the generated stacking, using the Central Composite Complete methodology, CCC. In this study, the peak (Cp) and base (Cb) current, wire feed speed during peak (Vap), base (Vab) and welding speed (Vs) were varied. The ideal parameter presented was Cp=200A, Cb=100A, Vap=2.9cm/min, Vab=1.2cm/min and Vs=20cm/min. Tensile tests showed up to 15% greater resistance in the samples in the longitudinal section in the welding direction compared to the transverse direction. Hardness tests demonstrated up to 9% less hardness at the center of the stack compared to the top and bottom. The fracture analysis of the specimens showed ductile fracture.

Key-words:
Welding; Additive manufacturing; VP50IM; GTAW pulsed; Forming profile

Chemical Element	Ni	Mn	Si	Cr	Mo
wt [%]	2.7	1.8	0.9	0.3	0.3

Level	C_p [A]	C_b [A]	Va_p [m/min]	Va_b [m/min]	Vs [cm/min]
Low	175	75	2.2	1.1	15
Medium	200	100	2.4	1.2	20
High	225	125	2.6	1.3	25

Level	C_p [A]	C_b [A]	Va_p [m/min]	Va_b [m/min]	Vs [cm/min]	Level	C_p [A]	C_b [A]	Va_p [m/min]	Va_b [m/min]	Vs [cm/min]
1	175	125	2.2	1.3	25	27	225	125	2.6	1.1	15
2	175	75	2.6	1.3	15	28	200	100	2.4	1	20
3	200	100	2.4	1.2	20	29	200	40	2.4	1.2	20
4	175	75	2.2	1.1	15	30	200	100	2.4	1.2	20
5	175	75	2.2	1.3	15	31	175	75	2.6	1.1	25
6	225	125	2.2	1.1	25	32	225	125	2.6	1.3	25
7	200	100	2.4	1.2	8	33	225	75	2.2	1.1	25
8	175	75	2.2	1.3	25	34	200	100	2.4	1.2	20
9	200	100	1.9	1.2	20	35	225	75	2.6	1.1	15
10	175	125	2.6	1.3	25	36	175	75	2.6	1.1	15
11	175	125	2.6	1.3	15	37	140	100	2.4	1.2	20
12	200	100	2.4	1.2	20	38	175	125	2.6	1.1	25
13	225	125	2.2	1.3	25	39	200	100	2.9	1.2	20
14	225	75	2.2	1.3	25	40	175	75	2.2	1.1	25
15	225	125	2.6	1.1	25	41	175	75	2.6	1.3	25
16	260	100	2.4	1.2	20	42	225	75	2.2	1.1	15
17	200	100	2.4	1.2	20	43	225	125	2.6	1.3	15
18	200	100	2.4	1.2	20	44	225	75	2.2	1.3	15
19	200	100	2.4	1.2	20	45	200	100	2.4	1.2	32
20	175	125	2.6	1.1	15	46	200	100	2.4	1.2	20
21	200	100	2.4	1.43	20	47	225	75	2.6	1.3	25
22	175	125	2.2	1.3	15	48	225	75	2.6	1.1	25
23	175	125	2.2	1.1	15	49	225	125	2.2	1.1	15
24	175	125	2.2	1.1	25	50	200	100	2.4	1.2	20
25	200	160	2.4	1.2	20	51	225	75	2.6	1.3	15
26	200	100	2.4	1.2	20	52	225	125	2.2	1.3	15

Process Parameters	Value
Peak current	200 A
Base Current	100 A
Welding Tension (average)	14 V
Welding speed	20 cm/min
Peak of frequency	10 Hz
Base of frequency	10 Hz
Polarity	CC -
Shielding gas	Argon; 12 L/min
Nozzle diameter	10 mm
Electrode (W+2%ThO2)	Ø 2.4 mm
Electrode tip angle	60º
Arc length	3 mm
Wire feed rate (VP50IM)	Ø 1.2 mm
Wire feed rate (peak)	2.9 m/min
Wire feed rate (base)	1.2 m/min
Wire incidence angle (α1)	15º
Torch incidence angle (β1)	75º
Angle between torch and wire (θ1)	90º

Level	b [mm]	h [mm]	r [mm/mm]	Level	b [mm]	h [mm]	r [mm/mm]	Level	b [mm]	h [mm]	r [mm/mm]
1	4.14	1.94	0.469	19	3.56	2.95	0.829	37	-	-	-
2	4.65	3.23	0.695	20	4.72	3.6	0.763	38	3.03	2.86	0.944
3	4.81	2.43	0.505	21	4.73	2.83	0.598	39	4.03	2.68	0.665
4	4.66	2.67	0.573	22	4.92	2.92	0.593	40	-	-	-
5	4.6	2.84	0.617	23	4.56	2.81	0.616	41	-	-	-
6	7.32	1.37	0.187	24	4.01	2.15	0.536	42	4.9	2.64	0.539
7	-	-	-	25	6.02	2.21	0.367	43	5.34	2.73	0.511
8	3.89	2.66	0.684	26	4.23	2.52	0.596	44	6.12	2.5	0.408
9	5.3	1.98	0.374	27	6.72	2.31	0.344	45	3.4	2.06	0.606
10	4.17	2.24	0.537	28	4.85	2.22	0.458	46	4.71	2.31	0.490
11	4.82	2.86	0.593	29	-	-	-	47	4.62	2.12	0.459
12	4.67	2.41	0.516	30	4.88	2.51	0.514	48	4.4	2.111	0.480
13	3.99	2.4	0.602	31	-	-	-	49	5.93	2.48	0.418
14	3.99	2.4	0.602	32	4.31	2.33	0.541	50	3.83	2.63	0.687
15	4.61	2.28	0.495	33	5.47	1.66	0.303	51	5.16	3.19	0.618
16	6.3	1.98	0.314	34	4.36	2.72	0.624	52	8.96	2.03	0.227
17	4.16	2.54	0.611	35	5.37	2.92	0.544
18	4.03	2.66	0.660	36	3.65	2.79	0.764

NÍVEL	AREA1 [mm]	AREA2 [mm]	r= AREA2/ AREA1	NÍVEL	AREA1 [mm]	AREA2 [mm]	r= AREA2/ AREA1	NÍVEL	AREA1 [mm]	AREA2 [mm]	r= AREA2/ AREA1
1	-	-	-	19	8.89	10.46	0.85	37	-	-	-
2	-	-	-	20	-	-	-	38	7.26	8.54	0.85
3	8.83	11.75	0.75	21	-	-	-	39	9.09	10.77	0.84
4	10.32	12.59	0.82	22	-	-	-	40	-	-	-
5	10.55	13.03	0.81	23	10.18	12.81	0.79	41	-	-	-
6	-	-	-	24	6.58	8.61	0.76	42	10.01	12.82	0.78
7	-	-	-	25	-	-	-	43	10.91	14.52	0.75
8	-	-	-	26	8.55	10.63	0.80	44	-	-	-
9	-	-	-	27	-	-	-	45	-	-	-
10	7.24	9.25	0.78	28	-	-	-	46	-	-	-
11	11.18	13.68	0.82	29	-	-	-	47	-	-	-
12	8.74	11.36	0.77	30	-	-	-	48	-	-	-
13	7.14	9.41	0.76	31	-	-	-	49	-	-	-
14	7.14	9.41	0.76	32	-	-	-	50	8.12	10.06	0.81
15	-	-	-	33	-	-	-	51	12.79	16.15	0.79
16	-	-	-	34	9.45	11.84	0.80	52	-	-	-
17	8.31	10.51	0.79	35	-	-	-
18	8.55	10.73	0.80	36	-	-	-

	TRANSVERSAL SAMPLE			LONGITUDINAL SAMPLE
Bead N°	Area [mm²]	Area [%]	Total Area [%]	Area [mm²]	Area [%]	Total Area [%]
33	20.7	6%	100%	-	-	-
32	16.21	4%	94%	-	-	-
31	15.82	4%	90%	-	-	-
30	10.27	3%	86%	-	-	-
29	8.08	2%	83%	-	-	-
28	10.33	3%	81%	-	-	-
27	8.89	2%	78%	-	-	-
26	12.29	3%	75%	-	-	-
25	7.73	2%	72%	-	-	-
24	10.33	3%	70%	-	-	-
23	12.49	3%	67%	-	-	-
22	11.55	3%	64%	-	-	-
21	12.61	3%	60%	-	-	-
20	9.29	3%	57%	-	-	-
19	14.38	4%	54%	-	-	-
18	11.55	3%	50%	-	-	-
17	13.76	4%	47%	-	-	-
16	11.54	3%	44%	-	-	-
15	12.74	3%	40%	-	-	-
14	10.6	3%	37%	-	-	-
13	10.36	3%	34%	-	-	-
12	9.72	3%	31%	18.11	15%	100%
11	10.25	3%	28%	12.9	11%	85%
10	8.65	2%	26%	9.78	8%	74%
9	9.29	3%	23%	7.13	6%	66%
8	12.75	3%	21%	9.81	8%	60%
7	14.88	4%	17%	8.64	7%	52%
6	11.85	3%	13%	14.18	12%	44%
5	13.92	4%	10%	13.29	11%	32%
4	7.52	2%	6%	6.76	6%	21%
3	8.31	2%	4%	10.82	9%	16%
2	4.49	1%	2%	4.29	4%	6%
1	2.03	1%	1%	3.36	3%	3%

	Fe [Wt%]	Ni [Wt%]	Mn [Wt%]	Si [Wt%]	Cr [Wt%]	Mo [Wt%]
Substrate	98.3	-	1.7	-	-	-
A Area	95.4	2.1	1.8	0.1	0.3	-
B Area	95.1	2.4	1.4	0.3	0.3	0.4
C area	95.1	2.5	1.5	0.3	0.3	0.4

	Yelding Stress [MPa]	Tensile Stress [MPa]	Area reduction [%]
A 1	633.25±32	642.5±32	39.1±2
A 2	562.75±28	655.9±34	37.2±2
B 1	529.80±29	638.8±31	34.8±2
B 2	514.14±26	634.1±31	38.0±2

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