Experimental investigations on the effect of wire arc additive manufacturing process parameters on the layer geometry of Inconel 825

Wire Arc Additive Manufacturing underwent remarkable development in the past decade. In the present work effect of welding parameters on additively deposited layer width is investigated. MIG welding is chosen for the present study and Inconel 825 having high industrial application is selected as wire spool. This paper is concentrating on the effect of weld parameters on additively deposited layer width using the Taguchi method. Waviness, weld cracks, porosity, and discontinuity of weld bead of a surface can be reduced by selection and optimising the parameters; otherwise, irregular shapes will come during the manufacturing of thin or thick wall construction by Wire Arc Additive Manufacturing. L9 Orthogonal array is used in Taguchi for the experimentation to analyze input parameters, namely, Welding speed, Wire feed speed and Voltage. Best parameter combination and significant parameters are obtained from the main effect plot and analysis of variance respectively. A mathematical model on the response variable is generated using a linear regression model. At 0.55 m/min welding velocity, 4 m/min Wire feed speed and 18 V Voltage is having least bead Width of 3.07 mm length. 0.25 m/min welding velocity, 8 m/min Wire feed speed and 28 V Voltage is having highest bead Width of 15.83 mm length. Confirmation tests are carried out after obtaining optimized parameters and results are correlated with obtained results. (C) 2019 Elsevier Ltd. All rights reserved.