Optimization of porosity and surface roughness of CMT-P wire arc additive manufacturing of AA2024 using response surface methodology and NSGA-Ⅱ
A novel cold metal transfer and pulse (CMT-P) hybrid arc technology was introduced for additive manufacturing of high-strength aluminum alloy 2024 (AA2024). The effects of process parameters, namely the wire-feed speed, travel speed, and CMT/P ratio (ratio of number of CMT stages to pulse stages in...
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| Format: | Article |
| Language: | English |
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Elsevier
2023-05-01
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| Series: | Journal of Materials Research and Technology |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785423009535 |
| _version_ | 1797798757715148800 |
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| author | Zhiqiang Zhang Junpei Yan Xuecheng Lu Tiangang Zhang Hao Wang |
| author_facet | Zhiqiang Zhang Junpei Yan Xuecheng Lu Tiangang Zhang Hao Wang |
| author_sort | Zhiqiang Zhang |
| collection | DOAJ |
| description | A novel cold metal transfer and pulse (CMT-P) hybrid arc technology was introduced for additive manufacturing of high-strength aluminum alloy 2024 (AA2024). The effects of process parameters, namely the wire-feed speed, travel speed, and CMT/P ratio (ratio of number of CMT stages to pulse stages in a cycle), on the porosity and surface roughness of AA2024 CMT-P additive manufacturing were systematically investigated using the response surface methodology and an improved non-dominated sorting genetic algorithm (NSGA). The results showed that the wire-feed speed had the greatest effect on the porosity and surface roughness. The porosity initially decreased and then increased with an increase in the wire-feed speed. However, the surface roughness decreased with an increase in the wire-feed speed. Moreover, the porosity was reduced with a decrease in the travel speed. With an increasing travel speed, the surface roughness initially decreased and then increased. Furthermore, for both porosity and surface roughness, the best results were obtained at a CMT/P ratio of 1/4. Thus, high porosity and surface roughness in the additive-manufactured parts were caused by high values of wire-feed speed, travel speed, and CMT/P ratio. In addition, using the optimized process parameters, additive parts with low porosity and low surface roughness could be produced. |
| first_indexed | 2024-03-13T04:08:40Z |
| format | Article |
| id | doaj.art-b961e3ebe37f48458d8e8d2bceb1618c |
| institution | Directory Open Access Journal |
| issn | 2238-7854 |
| language | English |
| last_indexed | 2024-03-13T04:08:40Z |
| publishDate | 2023-05-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Materials Research and Technology |
| spelling | doaj.art-b961e3ebe37f48458d8e8d2bceb1618c2023-06-21T06:57:20ZengElsevierJournal of Materials Research and Technology2238-78542023-05-012469236941Optimization of porosity and surface roughness of CMT-P wire arc additive manufacturing of AA2024 using response surface methodology and NSGA-ⅡZhiqiang Zhang0Junpei Yan1Xuecheng Lu2Tiangang Zhang3Hao Wang4School of Aeronautical Engineering, Civil Aviation University of China, Tianjin 300300, China; Corresponding author.School of Aeronautical Engineering, Civil Aviation University of China, Tianjin 300300, ChinaSchool of Aeronautical Engineering, Civil Aviation University of China, Tianjin 300300, China; Corresponding author.School of Aeronautical Engineering, Civil Aviation University of China, Tianjin 300300, ChinaTianjin Key Laboratory of High-Speed Cutting and Precision Machining, Tianjin University of Technology and Education, Tianjin 300222, ChinaA novel cold metal transfer and pulse (CMT-P) hybrid arc technology was introduced for additive manufacturing of high-strength aluminum alloy 2024 (AA2024). The effects of process parameters, namely the wire-feed speed, travel speed, and CMT/P ratio (ratio of number of CMT stages to pulse stages in a cycle), on the porosity and surface roughness of AA2024 CMT-P additive manufacturing were systematically investigated using the response surface methodology and an improved non-dominated sorting genetic algorithm (NSGA). The results showed that the wire-feed speed had the greatest effect on the porosity and surface roughness. The porosity initially decreased and then increased with an increase in the wire-feed speed. However, the surface roughness decreased with an increase in the wire-feed speed. Moreover, the porosity was reduced with a decrease in the travel speed. With an increasing travel speed, the surface roughness initially decreased and then increased. Furthermore, for both porosity and surface roughness, the best results were obtained at a CMT/P ratio of 1/4. Thus, high porosity and surface roughness in the additive-manufactured parts were caused by high values of wire-feed speed, travel speed, and CMT/P ratio. In addition, using the optimized process parameters, additive parts with low porosity and low surface roughness could be produced.http://www.sciencedirect.com/science/article/pii/S2238785423009535Wire arc additive manufacturingPorositySurface roughnessResponse surface methodologyNon-dominated sorting genetic algorithm |
| spellingShingle | Zhiqiang Zhang Junpei Yan Xuecheng Lu Tiangang Zhang Hao Wang Optimization of porosity and surface roughness of CMT-P wire arc additive manufacturing of AA2024 using response surface methodology and NSGA-Ⅱ Journal of Materials Research and Technology Wire arc additive manufacturing Porosity Surface roughness Response surface methodology Non-dominated sorting genetic algorithm |
| title | Optimization of porosity and surface roughness of CMT-P wire arc additive manufacturing of AA2024 using response surface methodology and NSGA-Ⅱ |
| title_full | Optimization of porosity and surface roughness of CMT-P wire arc additive manufacturing of AA2024 using response surface methodology and NSGA-Ⅱ |
| title_fullStr | Optimization of porosity and surface roughness of CMT-P wire arc additive manufacturing of AA2024 using response surface methodology and NSGA-Ⅱ |
| title_full_unstemmed | Optimization of porosity and surface roughness of CMT-P wire arc additive manufacturing of AA2024 using response surface methodology and NSGA-Ⅱ |
| title_short | Optimization of porosity and surface roughness of CMT-P wire arc additive manufacturing of AA2024 using response surface methodology and NSGA-Ⅱ |
| title_sort | optimization of porosity and surface roughness of cmt p wire arc additive manufacturing of aa2024 using response surface methodology and nsga ii |
| topic | Wire arc additive manufacturing Porosity Surface roughness Response surface methodology Non-dominated sorting genetic algorithm |
| url | http://www.sciencedirect.com/science/article/pii/S2238785423009535 |
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