Experimental Investigation and Optimization of Process Parameters of Self-Shielded Wire Powder Arc Additive Manufacturing on Low-Carbon Steel Through RSM

The choice of parameters is crucial in achieving the desired shape of the bead and reducing flaws in wire arc additive manufacturing. This study seeks to examine the influence of five input process parameters, specifically voltage, current, welding speed, nozzle-to-plate distance, and powder feed rate, at five different levels on the appearance of the bead in samples created using the self-shielded wire powder arc additive manufacturing process with low-carbon steel. Response surface methodology is used to analyze bead geometry, and a comparison analysis is performed to compare the effects of process parameters in conventional and advanced approaches. The appropriateness of the experimental design is evaluated by conducting an analysis of variance on a central composite design matrix that includes five process parameters. The observations indicate that the maximum width of the weld bead is 7.10 mm and the highest height is 4.49 mm. On the other hand, the minimum penetration depth is 1.09 mm, and the minimum dilution is 21%. The ideal input parameters are anticipated to be 21V voltage, 160A current, 5.5 mm/s welding speed, 15mm nozzle-to-plate distance, and 56 gms/min powder feed rate. The most influential component in determining various responses is current, followed by powder feed rate and welding speed. Scanning electron microscopy reveals that the weld bead region consists of both pearlite and Widmanstätten ferrite. Furthermore, the ultimate tensile strength and microhardness of samples produced utilizing self-shielding wire powder arc additive manufacturing are also assessed.