Influence of Printing Parameters on the Morphological Characteristics of Plasma Directed Energy-Deposited Stainless Steel
This study investigated the influence of printing parameters and strategies on the morphological characteristics of austenitic stainless steel beads deposited on carbon steel substrates, using plasma directed energy deposition (DED). The experimental setup varied the welding current, wire feed speed...
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MDPI AG
2024-10-01
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| Series: | Journal of Manufacturing and Materials Processing |
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| Online Access: | https://www.mdpi.com/2504-4494/8/5/233 |
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| author | Luis Segovia-Guerrero Antonio José Gil-Mena Nuria Baladés David L. Sales Carlota Fonollá María de la Mata María de Nicolás-Morillas |
| author_facet | Luis Segovia-Guerrero Antonio José Gil-Mena Nuria Baladés David L. Sales Carlota Fonollá María de la Mata María de Nicolás-Morillas |
| author_sort | Luis Segovia-Guerrero |
| collection | DOAJ |
| description | This study investigated the influence of printing parameters and strategies on the morphological characteristics of austenitic stainless steel beads deposited on carbon steel substrates, using plasma directed energy deposition (DED). The experimental setup varied the welding current, wire feed speed, and torch travel speed, and we analyzed three printing strategies: simple-linear, overlapping, and oscillating. Moreover, advanced 3D scanning and computational analysis were used to assess the key morphological features, including bead width and height. The results showed that the computational model developed by using parabolic assumptions accurately predicted the geometric outcomes of the overlapping beads. The oscillating printing strategy was the one that showed improved morphological uniformity and bead substrate wettability, so these features were used for multi-layer component manufacturing. The use of equivalent wavelength–amplitude values resulted in maximum combinations of bead height and width. Moreover, cost-effective carbon steel substrates were feasibly used in microstructural and elemental analyses, with the latter ones confirming the alignment of the bead composition with the wire-fed material. Overall, this study provides practical insights for optimizing plasma DED processes, thus enhancing the efficiency and quality of metal component manufacturing. |
| format | Article |
| id | doaj-art-5b781cbb87884c2ebd40bdb1188f129c |
| institution | OA Journals |
| issn | 2504-4494 |
| language | English |
| publishDate | 2024-10-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Journal of Manufacturing and Materials Processing |
| spelling | doaj-art-5b781cbb87884c2ebd40bdb1188f129c2025-08-20T02:11:11ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942024-10-018523310.3390/jmmp8050233Influence of Printing Parameters on the Morphological Characteristics of Plasma Directed Energy-Deposited Stainless SteelLuis Segovia-Guerrero0Antonio José Gil-Mena1Nuria Baladés2David L. Sales3Carlota Fonollá4María de la Mata5María de Nicolás-Morillas6INNANOMAT Group, Department of Industrial Engineering and Civil Engineering, IMEYMAT, Algeciras School of Engineering and Technology, University of Cádiz, Ramón Puyol Ave., 11202 Algeciras, SpainDepartment of Electrical Engineering, Algeciras School of Engineering and Technology, University of Cádiz, Ramón Puyol Ave., 11202 Algeciras, SpainIEG Group, Department of Industrial Engineering and Civil Engineering, IMEYMAT, Algeciras School of Engineering and Technology, University of Cádiz, Ramón Puyol Ave., 11202 Algeciras, SpainINNANOMAT Group, Department of Materials Science and Metallurgical Engineering and Inorganic Chemistry, IMEYMAT, Algeciras School of Engineering and Technology, University of Cádiz, Ramón Puyol Ave., 11202 Algeciras, SpainINNANOMAT Group, Department of Materials Science and Metallurgical Engineering and Inorganic Chemistry, IMEYMAT, Algeciras School of Engineering and Technology, University of Cádiz, Ramón Puyol Ave., 11202 Algeciras, SpainINNANOMAT Group, Department of Materials Science Metallurgical Engineering and Inorganic Chemistry, IMEYMAT, Faculty of Sciences, University of Cádiz, Universidad de Cádiz Ave., 11510 Puerto Real, SpainINNANOMAT Group, Department of Materials Science and Metallurgical Engineering and Inorganic Chemistry, IMEYMAT, Algeciras School of Engineering and Technology, University of Cádiz, Ramón Puyol Ave., 11202 Algeciras, SpainThis study investigated the influence of printing parameters and strategies on the morphological characteristics of austenitic stainless steel beads deposited on carbon steel substrates, using plasma directed energy deposition (DED). The experimental setup varied the welding current, wire feed speed, and torch travel speed, and we analyzed three printing strategies: simple-linear, overlapping, and oscillating. Moreover, advanced 3D scanning and computational analysis were used to assess the key morphological features, including bead width and height. The results showed that the computational model developed by using parabolic assumptions accurately predicted the geometric outcomes of the overlapping beads. The oscillating printing strategy was the one that showed improved morphological uniformity and bead substrate wettability, so these features were used for multi-layer component manufacturing. The use of equivalent wavelength–amplitude values resulted in maximum combinations of bead height and width. Moreover, cost-effective carbon steel substrates were feasibly used in microstructural and elemental analyses, with the latter ones confirming the alignment of the bead composition with the wire-fed material. Overall, this study provides practical insights for optimizing plasma DED processes, thus enhancing the efficiency and quality of metal component manufacturing.https://www.mdpi.com/2504-4494/8/5/233additive manufacturingWAAMplasma arcaustenitic stainless steelwettabilityprocess optimization |
| spellingShingle | Luis Segovia-Guerrero Antonio José Gil-Mena Nuria Baladés David L. Sales Carlota Fonollá María de la Mata María de Nicolás-Morillas Influence of Printing Parameters on the Morphological Characteristics of Plasma Directed Energy-Deposited Stainless Steel Journal of Manufacturing and Materials Processing additive manufacturing WAAM plasma arc austenitic stainless steel wettability process optimization |
| title | Influence of Printing Parameters on the Morphological Characteristics of Plasma Directed Energy-Deposited Stainless Steel |
| title_full | Influence of Printing Parameters on the Morphological Characteristics of Plasma Directed Energy-Deposited Stainless Steel |
| title_fullStr | Influence of Printing Parameters on the Morphological Characteristics of Plasma Directed Energy-Deposited Stainless Steel |
| title_full_unstemmed | Influence of Printing Parameters on the Morphological Characteristics of Plasma Directed Energy-Deposited Stainless Steel |
| title_short | Influence of Printing Parameters on the Morphological Characteristics of Plasma Directed Energy-Deposited Stainless Steel |
| title_sort | influence of printing parameters on the morphological characteristics of plasma directed energy deposited stainless steel |
| topic | additive manufacturing WAAM plasma arc austenitic stainless steel wettability process optimization |
| url | https://www.mdpi.com/2504-4494/8/5/233 |
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