Browsing by Author "SAADAWI, HASSAN"
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Item A STUDY ON THE WIRE ARC ADDITIVE MANUFACTURING OF DUPLEX STAINLESS STEEL PLATES: OPTIMIZATION OF PROCESS PARAMETERS AND INVESTIGATION OF MECHANICAL PROPERTIES(2022-03-01) SAADAWI, HASSAN; Konca, Erkan; Tur, KâzımIn recent years, additive manufacturing (AM) for metals, which is used to create products using layer-by-layer deposition of materials, has been a subject of interest as a means of enhancing the efficiency of manufacturing processes in various industries. In this thesis, super duplex stainless steel parts have been wire arc additively manufactured (WAAM) using the cold metal transfer welding technique. To obtain the optimum combination of additive manufacturing parameters (voltage, current and speed) that yields the desired bead quality, response surface method has been used to build statistical models based on numerical simulation of additive welding process. COMSOL Multiphysics 5.5 software has been used to perform the experimental instead of real process and Expert-Design software was used to obtain the statistical models. The optimal values of the controlled variables were found as 200 amperes and 15 volts for current and voltage, and 10 mm/s for welding speed. Then, the fracture toughness tests using the single edge notched tension (SENT) specimens were implemented at a sub-zero temperature. Fracture toughness data has been used to establish crack-growth resistance curves for both, as-received rolled plate and additively manufactured parts and compare the results based on J-integral (energy release rate). The J-integral value at the initiation of stable crack growth (Ji) of SDSS Grade 2507 as-received plate specimens is approximately 17% higher than the (Ji) value of WAAM’d DSS Grade 2209 and 31% higher than the (Ji) value of WAAM’d SDSS Grade 2509.