Optimization of Double-Wire Mig Based Shaped Metal Deposition Process Parameters OF3-D Printed AISI 309L Parts

MIG-welding plus cold-wire feed (CWF) based on 3D-printing-shaped metal deposition (SMD) is a technique of relatively new technologies for additive manufactured parts, which enables to create components in the form of near-net shaped parts using the metal inert gas method. The SMD technique is made by depositing a main wire plus cold feed wire melted by arc welding heat. In this paper, the experimental setup consists of MIG-welding plus cold wire feed and 3-axis machine to be able to apply the deposition process paths. The current work focused on investigating the effect of deposition parameters on the wall bead geometry and deposited wall hardness of the deposited specimens. The controlled input parameters in this work were melting current, traveling speed, and wire feed ratio as a new parameter. The results were analyzed by statistical technique, i.e. analysis of variance and signal/noise ratio. Confirmatory test had been carried out to achieve the validity of results. The results showed that the wire ratio contributes 49.42% towards the overall variation noticed within removed layer thickness. The traveling speed contributes 34.15% of the overall variation noticed within removed layer thickness. Wire feed ratio contributes 59.22% towards the overall variation noticed within hardness. The traveling speed contributes 38.31% of the overall variation noticed within hardness. The optimal value of hardness is 283.521, whereas total removed layer is 0.5791. From the results, it is clear that the wire feed ratio greatly affects the deposited parts quality, and hence this parameter is considered as a new addition to the shaped metal deposition technique using the 3D-SMD plus a cold wire feed