Manufacturing Technology 2022, 22(1):59-70 | DOI: 10.21062/mft.2022.001

Parametric Optimisation of Micro Plasma Welding for Wire Arc Additive Manufacturing by Response Surface Methodology

Nor Ana Rosli ORCID...1, Mohd Rizal Alkahari ORCID...1,2, Faiz Redza Ramli ORCID...1,3, Mohd Fadzli bin Abdollah ORCID...1,3, Syahibudil Ikhwan Abdul Kudus ORCID...4, Safarudin Gazali Herawan ORCID...5
1 Fakulti Kejuruteraan Mekanikal, Universiti Teknikal Malaysia Melaka Hang Tuah Jaya, 76100, Durian Tunggal, Melaka, Malaysia
2 Advanced Manufacturing Center, Universiti Teknikal Malaysia Melaka, Hang Tuah Jaya, 76100 Durian Tunggal, Melaka, Malaysia
3 Center for Advanced Research on Energy, Universiti Teknikal Malaysia Melaka, Hang Tuah Jaya, 76100 Durian Tunggal, Melaka, Malaysia
4 Fakulti Teknologi Kejuruteraan Mekanikal dan Pembuatan, Universiti Teknikal Malaysia Melaka, Hang Tuah Jaya, 76100, Durian Tunggal, Melaka, Malaysia
5 Industrial Engineering Department, Fakulti Kejuruteraan, Universitas Bina Nusantara, Jakarta, 11430, Indonesia

High deposition rate with minimal heat input is one of the primary emphases in wire arc additive manufacturing. This study aims to determine the optimal input parameters of micro plasma welding for single-layer deposition. The stability of a single layer is crucial as it serves as the foundation relative to the deposition of layers to avoid a discontinuous multi-layer material. The study focuses on wire feeding speed, welding speed, and pulse and their interaction between the input and response variables. Based on the study, the regression equation between the three key parameters and the response using the Box-Behnken Design response surface methodology was proposed. The outcome demonstrates that the op-timized sample deposition produces a smooth surface appearance with no apparent defects.

Keywords: additive manufacturing, 3D printing, wire arc additive manufacturing, micro plasma arc welding, response surface methodology
Grants and funding:

The authors acknowledge the financial support from Zamalah Scheme, Universiti Teknikal Malaysia Melaka.

Received: July 15, 2021; Revised: December 18, 2021; Accepted: January 20, 2022; Prepublished online: January 28, 2022; Published: February 26, 2022  Show citation

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Rosli NA, Alkahari MR, Ramli FR, Fadzli bin Abdollah M, Ikhwan Abdul Kudus S, Gazali Herawan S. Parametric Optimisation of Micro Plasma Welding for Wire Arc Additive Manufacturing by Response Surface Methodology. Manufacturing Technology. 2022;22(1):59-70. doi: 10.21062/mft.2022.001.
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