Development of a NC-Controlled GTAW-Based Wire Arc Additive Manufacturing System for Using Friction Stir Extrusion Recycled Wires
This study investigates the feasibility of using friction stir extrusion (FSE) recycled aluminum wires as filler metals for gas tungsten arc welding (GTAW) and additive manufacturing applications. A NC-controlled GTAW feeding system was developed to enable the deposition of these recycled wires. The...
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MDPI AG
2024-12-01
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| Series: | Machines |
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| Online Access: | https://www.mdpi.com/2075-1702/13/1/10 |
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| author | Gustavo H. S. F. L. Carvalho Gianni Campatelli Bruno Silva Cota Davide Campanella Rosa Di Lorenzo |
| author_facet | Gustavo H. S. F. L. Carvalho Gianni Campatelli Bruno Silva Cota Davide Campanella Rosa Di Lorenzo |
| author_sort | Gustavo H. S. F. L. Carvalho |
| collection | DOAJ |
| description | This study investigates the feasibility of using friction stir extrusion (FSE) recycled aluminum wires as filler metals for gas tungsten arc welding (GTAW) and additive manufacturing applications. A NC-controlled GTAW feeding system was developed to enable the deposition of these recycled wires. The effect of cleaning the machining chips before the FSE process on the quality of the manufactured wires and the resulting welded beads was evaluated. Wires produced from uncleaned chips and cleaned chips were compared in terms of their external appearance, ductility, and the presence of porosity after the weld deposition. The results showed that cleaning the chips before the FSE process is crucial for obtaining more uniform wires with better ductility. Automatic GTAW deposition using cleaned wires resulted in significantly improved bead geometry, reduced external porosity, and overall better quality compared to uncleaned wires. However, both wire types exhibited internal porosity, with uncleaned wires showing the worst performance. The findings demonstrate the potential of using FSE recycled aluminum wires for welding and additive manufacturing while highlighting the importance of chip cleaning and the need for further optimization to minimize porosity in the deposited material. |
| format | Article |
| id | doaj-art-fb8e03712beb47ca9148c7dcbc7d029d |
| institution | Kabale University |
| issn | 2075-1702 |
| language | English |
| publishDate | 2024-12-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Machines |
| spelling | doaj-art-fb8e03712beb47ca9148c7dcbc7d029d2025-01-24T13:39:07ZengMDPI AGMachines2075-17022024-12-011311010.3390/machines13010010Development of a NC-Controlled GTAW-Based Wire Arc Additive Manufacturing System for Using Friction Stir Extrusion Recycled WiresGustavo H. S. F. L. Carvalho0Gianni Campatelli1Bruno Silva Cota2Davide Campanella3Rosa Di Lorenzo4Department of Industrial Engineering, University of Florence, Via di Santa Marta 3, 50139 Firenze, ItalyDepartment of Industrial Engineering, University of Florence, Via di Santa Marta 3, 50139 Firenze, ItalyInstituto de Engenharias Integradas, Universidade Federal de Itajubá, Distrito Industrial, Itabira 35903-087, BrazilDepartment of Engineering, University of Palermo, Via delle Scienze, 90128 Palermo, ItalyDepartment of Engineering, University of Palermo, Via delle Scienze, 90128 Palermo, ItalyThis study investigates the feasibility of using friction stir extrusion (FSE) recycled aluminum wires as filler metals for gas tungsten arc welding (GTAW) and additive manufacturing applications. A NC-controlled GTAW feeding system was developed to enable the deposition of these recycled wires. The effect of cleaning the machining chips before the FSE process on the quality of the manufactured wires and the resulting welded beads was evaluated. Wires produced from uncleaned chips and cleaned chips were compared in terms of their external appearance, ductility, and the presence of porosity after the weld deposition. The results showed that cleaning the chips before the FSE process is crucial for obtaining more uniform wires with better ductility. Automatic GTAW deposition using cleaned wires resulted in significantly improved bead geometry, reduced external porosity, and overall better quality compared to uncleaned wires. However, both wire types exhibited internal porosity, with uncleaned wires showing the worst performance. The findings demonstrate the potential of using FSE recycled aluminum wires for welding and additive manufacturing while highlighting the importance of chip cleaning and the need for further optimization to minimize porosity in the deposited material.https://www.mdpi.com/2075-1702/13/1/10GTAWfriction stir extrusionchip recyclingcircular economy |
| spellingShingle | Gustavo H. S. F. L. Carvalho Gianni Campatelli Bruno Silva Cota Davide Campanella Rosa Di Lorenzo Development of a NC-Controlled GTAW-Based Wire Arc Additive Manufacturing System for Using Friction Stir Extrusion Recycled Wires Machines GTAW friction stir extrusion chip recycling circular economy |
| title | Development of a NC-Controlled GTAW-Based Wire Arc Additive Manufacturing System for Using Friction Stir Extrusion Recycled Wires |
| title_full | Development of a NC-Controlled GTAW-Based Wire Arc Additive Manufacturing System for Using Friction Stir Extrusion Recycled Wires |
| title_fullStr | Development of a NC-Controlled GTAW-Based Wire Arc Additive Manufacturing System for Using Friction Stir Extrusion Recycled Wires |
| title_full_unstemmed | Development of a NC-Controlled GTAW-Based Wire Arc Additive Manufacturing System for Using Friction Stir Extrusion Recycled Wires |
| title_short | Development of a NC-Controlled GTAW-Based Wire Arc Additive Manufacturing System for Using Friction Stir Extrusion Recycled Wires |
| title_sort | development of a nc controlled gtaw based wire arc additive manufacturing system for using friction stir extrusion recycled wires |
| topic | GTAW friction stir extrusion chip recycling circular economy |
| url | https://www.mdpi.com/2075-1702/13/1/10 |
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