May 2022 Volume 4

FORGING RESEARCH

Project Title: High temperature properties of wire-arc additively manufactured 410 stainless steel (Final Report) Organization/Initiative: Georgia Southern University Email: bsilwal@georgiasouthern.edu Lead Investigator: Bishal Silwal Industry Advisor: Prabir Chaudhary Student Name: Alex Reichenbach and Marcus Perez Project Title: High temperature properties of wire-arc additively manufactured 410 stainless steel (Final Report) Proposal submitted: 2-15-2021 Organization/Initiative: Georgia Southern University Federal ID # 58-6002059 Phone: 9124780542 Email: bsilwal@georgiasouthern.edu Lead Investigator: Bishal Silwal Industry Advisor: Prabir Chaudhary Student Name: Alex Reichenbach and Marcus Perez Final Report

The objective of the micro grant proposal is to investigate the high temperature properties of wire-arc additively manufactured 410 martensitic stainless steel. 410 stainless steel can be used for steam turbine buckets, gas turbine compressor blades, and petrochemical equipment. Wire-arc additive manufacturing is a rapid, low cost direct energy deposition technology. The reported speed of WAAM is in the range of 5 lb/hr to 30 lb/hr. It would be beneficial for the forging industry to fabricate the appropriate tooling rapidly using such technology. 410 stainless steel provides the necessary hardness for tooling applications, it has low cost, good machinability and printability however it hasn't been used for the forging/tooling application yet, although the steel has potential. The chemical composition of the 410 stainless steel is shown in Table 1. The objective of the micro grant proposal is to investigate the high temperature properties of wire-arc additively manufactured 410 martensitic stainless steel. 410 stainless steel can be used for steam turbine buckets, gas turbine compressor blades, and petrochemical equipment. Wire-arc additive manufacturing is a rapid, low cost direct energy deposition technology. The reported speed of WAAM is in the range of 5 lb/ r t 30 lb/hr. It would b beneficial f r the forging industry to fabricate the appropriate tooling rapidly using such technology. 410 stainless steel provides the necessary hardness for tooling applications, it has low cost, good machinability and printability however it hasn't been used for the forging/tooling application yet, although the steel has potential. The chemical composition of the 410 stainless steel is shown in Table 1. Table 1: Chemical Composition of the martensitic stainless-steel wire (balanced Fe) Element Ni Cr Si Mn C P S Cu Mo Wt. % 0.1 12.5 0.39 0.45 0.11 0.01 0.01 0.14 0.03 Our previous studies [1] have shown that 410 martensitic stainless steel have excellent room temperature mechanical properties when correct parameters are selected for the wire-arc additive manufacturing process, however the high temperature mechanical properties of WAAM fabricated 410 stainless steel is scarc . The specimens f r high perature t sting was sectioned from the wire-arc additive manufacturing part to test the high temperature mechanical properties, mainly high temperature compression. The micro grant has enable the mechanical engineering students’ involvement in the training, participation and education related to forging thus preparing them for careers in the forging industry. Several bead-on-plate experiments were performed to deposit a two bead layer wall. The Gas Metal Arc Welding (GMAW) variables (surface tensi transfer® ), s i lding gas (Ar-CO2 and Ar-N2) and center to center distance between the weld beads were adjusted. The wire-arc additive manufacturing toolpath can be generated manually or via the software. We recently acquired a toolpath planning software OCTOPUZ, thus the tool path for the Robot movement was made using OCTOPUZ. The round specimen for high temperature testing will be prepared from the WAAM fabricated part. Table 1: Chemical Composition of the martensitic stainless-steel wire (balanced Fe) Our previous studies [1] have shown that 410 martensitic stainless steel have excellent room temperature mechanical properties when correct parameters are selected for the wire-arc additive manufacturing process, however the high temperature mechanical properties of WAAM fabricated 410 stainless steel is scarce. The specimens for high temperature testing was sectioned from the wire-arc additive manufacturing part to test the high temperature

mechanical properties, mainly high temperature compression. The micro grant has enable the mechanical engineering students’ involvement in the training, participation and education related to forging thus preparing them for careers in the forging industry. Several bead-on-plate experiments were performed to deposit a two bead layer wall. The Gas Metal Arc Welding (GMAW) variables (surface tension transfer® ), shielding gas (Ar-CO2 and Ar-N2) and center to center distance between the weld beads were adjusted. The wire-arc additive manufacturing toolpath can be generated manually or via the software. We recently acquired a toolpath planning software OCTOPUZ, thus the tool path for the Robot movement was made using OCTOPUZ. The round specimen for high temperature testing will be prepared from the WAAM fabricated part. Experimental work: The preliminary tests were performed to obtain a suitable process parameter for wire-arc additive manufacturing process. A 0.045” wire diameter 410 stainless steel was used. The in house bead-on-plate was performed by a Lincoln R450 Power wave welder and Kuka KR6 R900 six-axis Robot (Fig 1) with a Tregaskiss robotic integration kit to complete the welding setup. The tool path programming is completed by slicing the part design in ultimaker Cura, an open source 3D printing slicing software, the resulting G-code is imported into Octopuz (a toolpath planning software) where it is translated into robot instruction and exported to the robot for execution.This allows us to rapidly go from part idea and design to welding and part production.

FIA MAGAZINE | MAY 2022 74