Investigation of the effects of process parameters in wire arc additive manufacturing method

Additive manufacturing technology is one of the most critical production methods of the Industry 4.0 revolution. Additive manufacturing technology, in which the three-dimensional printer principle is used, offers significant advantages over traditional production methods. The wire arc additive manufacturing method, which has advantages over other additive manufacturing types, is one of the fastest developing methods among additive manufacturing types. In addition to its many advantages, the correct determination of welding parameters in the wire arc additive manufacturing method is the factor that most affects the quality of the part to be produced. In this study, the effects of wire speed (current value), arc length (voltage value), and robot speed parameters on the mechanical properties of the manufactured part were investigated in the wire arc additive manufacturing method using ER-4043 aluminum alloy. Nine test pieces were produced in order to reach the ideal welding parameters. Nine parameter sets determined using the Taguchi experimental design method were used, and the best mechanical properties of the produced parts were aimed to be achieved. Firstly, the surfaces of these parts produced in the robotic production line were prepared with milling and grinding machines in order to carry out mechanical tests. After that, X-Ray radiographic pictures were taken to examine the porosity in their internal structures. Then, with the help of a wire erosion machine, the test samples were cut from the test piece plates according to the desired dimensions. Tensile strength tests, Charpy impact tests, and hardness tests were performed on the sample parts, and the mechanical strengths of the sample parts were determined. Finally, with the help of the Taguchi method, the welding parameters that have the most effect on the mechanical strengths of the test specimens were determined, and the welding parameter sets that provided the best mechanical strengths were determined. In the evaluation, it was observed that the most critical parameters affecting the mechanical strengths of the parts are arc length (voltage value) and wire speed (current value). It was seen that very few internal pores were formed in the test piece plates produced with the parameter sets that achieved the best mechanical strength values. The most effective result in tensile strength was achieved with the parameter set of 4 m/min wire speed, -30 arc length, and 60 cm/min robot speed. In elongation, it was seen that the part produced with the parameters of 5 m/min wire speed, -30 arc length, and 40 cm/min robot speed showed the best performance. Moreover, it was observed that the most effective result in impact resistance was obtained with 6 m/min wire speed, -30 arc length, and 50 cm/min robot speed parameter set.