Journal Articles

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Author: search.filters.author.Das, Alok Kumar

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    Development of wire arc additive manufactured Cu-Si alloy: study of microstructure and wear behavior
    (Springer Nature, 2023-02-21) Kazmi, Kashif Hasan; Sharma, Sumit K.; Das, Alok Kumar; Mandal, Amitava; Shukla, Amarish Kumar
    Wire arc additive manufacturing (WAAM) is an approach to develop unique and sophisticated design products in comparison to other traditional techniques. In the present study, the components of Cu-Si alloy have been developed using WAAM with a robotic gas metal arc welding technique. In this process, the current and voltage varied from 70 to 110 A and 17 to 19 V, respectively. The effect of process parameters on the microstructure, hardness, and wear behavior of components have been studied in details. The results show that the surface roughness of the components reduced with the increase in current and voltage. The microstructure of the uppermost surface of WAAM components shows columnar followed by dendritic with equiaxed morphology. The process parameter also affects the mechanical and wear resistance properties of WAAM components. The results show that the microhardness (from 100.03 to 160.03 HV) and wear resistance of the Cu-Si alloy component increase with the increases in current and voltage.
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    Wire arc additive manufacturing of ER-4043 aluminum alloy: effect of tool speed on microstructure, mechanical properties and parameter optimization
    (Springer Nature, 2023-05-23) Kazmi, Kashif Hasan; Sharma, Sumit K.; Das, Alok Kumar; Mandal, Amitava; Shukla, Amarish Kumar; Mandal, Ranjan
    Recent technological breakthroughs have had a significant impact on wire arc additive manufacturing (WAAM) technology in the metal manufacturing industry. Current and tool speed are the essential factors influencing the bead quality in WAAM, and experiments were conducted to optimize these parameters. Central composite design was applied for the deposition of beads, and their responses (bead width, height, depth of penetration and surface roughness) were measured using the coordinate measuring machine and 3D profilometer. Analysis of variance was applied to check the validity of the actual and predicted models. In this research, the morphology, microstructure, microhardness and wear behavior of the aluminum alloy ER-4043 were examined. Specimens were deposited using robotic gas metal arc welding (GMAW), using a 1.2 mm wire diameter, a constant current of 250 A and varying tool speed from 7 to 11 mm/s.
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    Wire arc additive manufacturing of ER-4043 aluminum alloy: evaluation of bead profile, microstructure, and wear behaviour
    (Springer Nature, 2023-07-13) Kazmi, Kashif Hasan; Das, Alok Kumar; Sharma, Sumit K.; Mandal, Amitava; Shukla, Amarish Kumar
    Wire arc additive manufacturing technique has a major transformation in metal manufacturing as a result of recent technological advancements. The present study is aimed at the deposition of the defects-free bead of ER-4043 aluminum alloy (aluminum–silicon alloy) by using wire arc additive manufacturing (WAAM) with robotic gas metal arc welding (GMAW) with varying current and tool speeds. The arc served as the heat source, and a 1.2-mm diameter of ER-4043 aluminum alloy wire was used as the raw material during bead deposition. The cross-section profile of the single bead in WAAM is essential for determining surface quality and dimensional accuracy. The cross-section profile of each bead was measured using a coordinate measuring machine (CMM) by taking multiple points on the surface of each bead. Points taken from each bead are fitted with Gaussian, logistic, parabola, and sine functions using the least square regression analysis to determine the geometry of the single bead. Moreover, the microstructure and mechanical properties of the deposited bead were investigated on selected parameters with a constant tool speed of 10 mm/s, varying heat input in terms of current from 153 A, 202 A, and 246 A of specimens A, B, and C, respectively. The detailed study shows the understanding of the effect of variation of current on the surface morphology, microstructure, hardness, and wear behavior of deposited beads.