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In a recent publication in the prestigious Journal Metals and Materials International, Dr Maheshwar Dwivedy, Associate Professor in the Department of Mechanical Engineering and Dr B Prasanna Nagasai, Post-Doctoral Researcher, delve into the intricate relationship between welding processes and the resulting microstructure and mechanical properties of Duplex Stainless-Steel parts fabricated through Wire Arc Additive Manufacturing.

The research paper, aptly titled “Influence of Welding Processes on the Microstructure and Mechanical Properties of Duplex Stainless-Steel Parts Fabricated by Wire Arc Additive Manufacturing,” illuminates the crucial factors that influence the quality and performance of components produced using this innovative manufacturing technique.

This collaborative effort not only enriches the academic community but also holds promising implications for the advancement of additive manufacturing technologies, particularly in the realm of Duplex Stainless-Steel fabrication. By unravelling the impact of different welding processes on the microstructural characteristics and mechanical behaviour of such components, the researchers offer valuable insights that can potentially enhance the efficiency and reliability of the manufacturing process.
The publication of this paper signifies a significant milestone in the ongoing exploration of material science and additive manufacturing techniques, highlighting the dedication and expertise of Dr Maheshwar Dwivedy and Dr B Prasanna Nagasai in pushing the boundaries of knowledge and innovation in the field.

Abstract

Direct energy deposition (DED) is an advanced additive manufacturing (AM) technique for producing large metal components in structural engineering. Its cost-effectiveness and high deposition rates make it suitable for creating substantial and complex parts. However, the mechanical and microstructural properties of these components can be influenced by the varying heat input and repeated thermal treatments associated with different welding procedures used during the deposition process. This study employed gas metal arc welding (GMAW) and cold metal transfer (CMT) arc welding techniques to fabricate cylindrical components from 2209 duplex stainless steel (DSS).

The research investigated the impact of these welding methods on the microstructure and mechanical properties of the 2209 DSS cylinders. The intricate thermal cycles and cooling rates inherent in the DED process significantly influenced the primary phase balance, ideally comprising 50% austenite and 50% ferrite. In components processed using GMAW, σ-phase formation was noted at the grain boundaries. Additionally, a slower cooling rate and extended time for solid-state phase transformations led to an increase in austenite content from the bottom to the top of the component. The cylinder fabricated using the CMT process exhibited fine austenite morphologies and a higher ferrite content compared to the GMW-processed cylinder.

Furthermore, the cylinder produced using the CMT process showed consistent properties across the building direction, unlike the components manufactured with the GMW process. In terms of tensile properties, hardness, and impact toughness, the cylinder produced using the CMT technique outperformed the one made with the GMW process.

Research in Layperson’s Terms

Over the last ten years, a new way of making things called additive manufacturing (AM) has become really popular, especially in industries like aerospace, oil, and gas. This technology builds parts layer by layer, which is a big change from traditional methods that often involve cutting away material to shape a part. One specific method of AM, called Directed Energy Deposition (DED), is particularly good at creating complex metal parts quickly and efficiently. A special kind of stainless steel called duplex stainless steel (DSS) is made of two types of microstructures, ferrite and austenite, which give it great strength and resistance to corrosion. This makes it ideal for use in demanding environments like the oil and gas industry.

A technique within DED called Wire Arc Additive Manufacturing (WAAM) is becoming a popular way to make large, strong metal parts like pipes and storage tanks. WAAM uses the same equipment as welding and can build parts by melting wire with an electric arc. It’s faster and cheaper than other AM methods. However, the process can change the structure of the metal, which affects its properties. For example, too much heat can reduce the amount of ferrite in the metal, making it less strong.

Researchers have been studying how different methods of WAAM, including ones that use less heat, affect the metal’s structure and properties. They’ve found that controlling the heat can lead to better mechanical properties, like higher strength and toughness. They’ve also looked at new technologies like digital twins (virtual models of the manufacturing process) to improve the stability and consistency of the process. In this study, researchers focused on making cylindrical parts from 2209 DSS using two different welding processes within WAAM: Gas Metal Arc Welding (GMAW) and Cold Metal Transfer (CMT).

They studied how these processes affected the metal’s structure and properties, like tensile strength, hardness, and toughness. The goal was to understand which process produces the best quality parts for industrial use. In summary, the research aims to improve the manufacturing of strong, corrosion-resistant metal parts using advanced AM techniques, making them more efficient and cost-effective for industries that need durable components.

Practical Implementation or the Social Implications Associated

The practical implementation of this research can revolutionise industrial manufacturing, especially in sectors like aerospace, oil and gas, automotive, and marine applications. Using WAAM with DSS, industries can produce lightweight, high-strength parts that withstand extreme environments, significantly improving efficiency and cost-effectiveness. WAAM’s ability to quickly produce customized and high-quality components also makes it ideal for rapid prototyping and repair, reducing lead times and overall production costs. Furthermore, WAAM is a more sustainable manufacturing method, generating less waste and utilizing recycled materials, contributing to eco-friendly production practices. The social implications are substantial, including the creation of new job opportunities and the need for specialized training programs to equip workers with advanced skills.

The economic impact is also notable, as WAAM enhances the competitiveness of companies, driving economic growth in high-tech industries. Innovation is fostered through advancements in manufacturing processes and materials science, leading to improved product performance and longevity, particularly in safety-critical applications. Additionally, the environmental benefits of reduced waste and potential use of recycled materials align with global sustainability goals. Overall, the adoption of WAAM can democratize the manufacturing landscape, making advanced technologies more accessible and affordable for smaller companies and startups, thereby fostering a more inclusive and innovative industrial environment.

Future Research Plans:
The upcoming work will focus on creating Functionally Graded Materials (FGMs) using Wire Arc Additive Manufacturing (WAAM) by merging various metals, including nickel, stainless steel, mild steel, Inconel 718, and AISI 410 MSS. The goal is to optimise material interfaces, refine deposition processes, and ensure structural integrity for high-performance applications.

Link to the article

In a groundbreaking initiative, the Directorate of IR & HS, along with the Department of Mechanical Engineering and Electrical and Electronics Engineering, successfully hosted the “Sakura Sangam: Indo Japan Joint Workshop,” a two-day virtual event held on July 29 and 30, 2024. This workshop, organised in collaboration with Toyo University, Japan and supported by SRM Global Consulting, aimed to foster academic collaboration and cultural exchange between India and Japan.

During the first day, participants delved into key subjects within Mechanical, Electrical, and Electronics engineering, engaging in dynamic sessions that facilitated knowledge exchange and exploration of the latest advancements in these critical fields. The workshop provided a platform for students and professionals alike to enhance their understanding and contribute to ongoing discussions about innovation and technology.

The second day of the workshop was particularly enriching. It featured talks and seminars highlighting the rich cultural heritage of both nations. Attendees had the unique opportunity to gain a deeper appreciation for the traditions and customs that define the Indo-Japanese relationship. Vice Chancellor Dr Manoj K. Arora explained the meaning of ‘Sakura Sangam.’ He noted that “Sakura” refers to cherry blossoms, which are highly cherished in Japanese culture and symbolise the beauty and fleeting nature of life. ‘Sangam’ means ‘coming together’ in Sanskrit. This introduction set the stage for the workshop’s focus on bringing people together and sharing cultures.
Professor discussed India’s reputation as an IT hub and Japan’s renowned manufacturing expertise. He suggested that by combining these strengths, we could share knowledge and strengthen our bonds. The professor then officially started the workshop with a brief introduction, outlining what we will cover over the next two days.

Dr P Vivekananda Shanmuganathan provided a detailed brief on the research activities at SRMAP, with a particular focus on Mechanical Engineering. He highlighted some of the prominent PhD scholars and their ongoing research projects, showcasing their contributions to advanced topics such as innovative manufacturing processes and robotics. This presentation underscored the university’s dedication to cutting-edge research and its role in advancing the field through the efforts of its talented scholars.
Dr Vitalram Rayankula presented his research on Inverse Kinematics, focusing on the “Two Degree of Freedom Manipulator,” a robotic arm with two independent movements. He discussed the challenges of motion planning, particularly when dealing with line-type obstacles. Dr. Rayankula compared scenarios where the manipulator encounters obstacles without collision to those where collisions occur, highlighting the importance of precise calculations and control algorithms for safe robotic operation.

Dr Kiran Kumar discussed electric vehicles (EVs) and their challenges compared to internal combustion engine (ICE) vehicles. He highlighted issues such as the efficiency of ICE components, the longer recharge time for EVs, and the need for additional lead-acid batteries to match the energy density of gasoline. Dr. Kumar emphasized the limitations of current battery technology, which impact the range, weight, and overall efficiency of EVs, while also noting the environmental benefits they offer.

Prof. Shinobu Yamaguchi explored Japan’s changing perspectives regarding India, emphasising the importance of mutual cultural understanding in today’s globalised world. She highlighted how Japan’s view of India has evolved significantly over time.

In addition to technical topics, the workshop also included career-oriented sessions designed to equip students with insights into the professional landscape. Industry experts provided guidance on internships, job prospects, and the latest trends influencing both the Japanese and Indian job markets.

The “Sakura Sangam” workshop proved to be a resounding success, fostering both academic and cultural ties and paving the way for future collaborations between educational institutions in India and Japan.

Dr M Sheikh Mohamed shared insights from his 14-year journey in Japan, focusing on both challenges and growth opportunities.
● Academic Background: Originally from Chennai, Dr. Mohamed completed his B.Sc., M.Sc., and M.Phil. in Biotechnology before moving to Japan.
● Language Challenges: He emphasised the complexity of learning Japanese, especially the kanji script, which can be daunting for newcomers.
● Cultural Adaptation: Dr. Mohamed discussed the importance of mutual respect and understanding in Japan, noting that being polite and helpful can go a long way in overcoming cultural barriers.
● Time Management: He admired the punctuality ingrained in Japanese society, where trains and trams run with remarkable precision.
● Earthquake Preparedness: Recounting an earthquake experience, he observed the calm and orderly manner in which people evacuated buildings, reflecting the nation’s preparedness and resilience.

Thamtoro Elias Dillan, Department of Mechanical Engineering, International Student from Indonesia, provided a detailed account of the key challenges and experiences faced by international students in Japan:
1. Language Barrier: The difficulty of mastering Japanese can be a significant hurdle for international students, impacting daily life and academic success.
2. Student Life: He highlighted the differences in student life between Japan and his home country, including the structure of academic programs and extracurricular activities.
3. Cost of Living: He discussed the relatively high cost of living in Japan, including accommodation, food, and transportation, and offered tips on managing expenses.
4. Location: The choice of university location can greatly affect the student experience, with major cities offering more opportunities but also higher living costs.
5. Help & Support: He stressed the importance of seeking help and support from university resources and local communities to navigate the challenges of living abroad.

Sankar San and Mr. Masahiro Koizumi, Senior Operating Officer of Forum Engineering and Managing Director of Cognavi India, discussed the evolving landscape of educational and career opportunities between Japan and India, focusing on the following aspects:
1. Opportunities in India for Japanese Students: They highlighted the growing interest among Japanese students in India’s IT and engineering sectors, offering diverse opportunities for learning and career growth.
2. Opportunities in Japan for Indian Students: They noted that Japan offers unique opportunities for Indian students, particularly in fields like robotics, engineering, and business management.
3. Identified Gaps: They discussed the gaps in mutual understanding and the challenges students face in adapting to different educational and cultural environments.
4. Changing Trends: They emphasised how initiatives like exchange programs and collaborative projects are bridging these gaps, fostering greater understanding and collaboration.

Sankar San and Jotish San detailed SRM’s strategic initiatives to integrate Japanese language and culture into their curriculum:
● Curriculum Integration: SRM AP has introduced Japanese language courses from the first year, aiming to equip students with the language skills needed for internships and job placements in Japan.
● Destination Japan Program: This program offers students opportunities to experience Japanese culture and work environments, enhancing their global competence.
● Internship and Placement Opportunities: They highlighted partnerships with Japanese companies, providing internships and placements for students, which can be pivotal for career development.
● SRM Group’s Vision: They concluded by sharing SRM’s broader vision of fostering international collaboration and preparing students for a globalized job market.

Ms. Aditi Jain, Director of International Relations and Higher Studies, has eloquently addressed the concept of internationalization and its potential benefits for students from both nations. She highlighted the invaluable partnerships at SRM AP, which foster cross-cultural exchanges and enhance academic collaboration. In her words, “Internationalization not only broadens academic horizons but also cultivates a deeper understanding and appreciation of diverse cultures, preparing students for a globalised world.” These initiatives are not just about enhancing educational experiences; they also empower students to develop a global perspective, essential for succeeding in today’s interconnected environment.

Dr Maheshwar Dwivedy, Associate Dean of Practice School, and Associate Professor, at the Department of Mechanical Engineering, SRM University-AP in collaboration with his post-doctoral scholar, Dr B Prasanna Nagasai, have joined forces to combine artificial intelligence with Cold Metal Transfer (CMT) Technology. Their research paper, “Cold Metal Transfer Technology – A Review of Recent Research Developments,” featured in the Q1 journal, Results in Engineering promises to make a significant impact on automobile, aerospace, oil and gas manufacturing industries, and that’s not all the research will also generate employment opportunities, and empower engineers to deliver enhanced services.

Abstract:

Cold Metal Transfer (CMT) technology has emerged as a promising welding technique, offering numerous advantages such as reduced heat input, minimal spatter, and enhanced control over the welding process. This paper provides a comprehensive review of recent research developments in CMT technology, focusing on its history, variants, recent advancements, and future perspectives. Initially, the paper traces the historical development of CMT welding, highlighting its evolution and the introduction of various CMT variants with distinct characteristics and applications. Recent studies have focused on optimising CMT process parameters to improve weld quality and productivity, leading to advancements in parameter control, arc stability, and wire-feeding mechanisms. Additionally, research has explored the microstructural evolution and mechanical properties of CMT-welded joints for both similar and dissimilar metals, providing insights into material compatibility, joint design, and performance under various conditions. Specific applications such as Laser-CMT hybrid welding, CMT cladding, CMT wire arc additive manufacturing, and CMT welding for repair across various materials are examined, demonstrating the versatility of CMT technology. This review also addresses the challenges and methodologies for defect reduction in CMT welding, along with recommendations for best practices. Furthermore, the paper discusses the integration of artificial intelligence in CMT welding, exploring opportunities for enhanced weld quality, economic, and social implications, and future research directions.

Practical and Social Implications:

The practical implementation of this research on Cold Metal Transfer (CMT) technology can significantly impact various industries, such as automotive, aerospace, oil and gas, and manufacturing. By optimising CMT welding parameters and integrating advanced features like arc length control and waveform modulation, industries can achieve higher weld quality, reduce defects, and enhance productivity. This can lead to more reliable and efficient manufacturing processes, resulting in cost savings and improved product performance. Social implications associated with this research include the potential for increased job opportunities and skill development in the welding and manufacturing sectors. As industries adopt advanced CMT technology, there will be a growing demand for skilled workers trained in these techniques. Additionally, improved welding quality and reduced defects can lead to safer and more durable products, enhancing overall public safety and satisfaction. The integration of artificial intelligence in CMT welding also opens up new avenues for innovation and technological advancements, fostering a culture of continuous improvement and progress in the manufacturing industry.

Collaborations:

Dr V Balasubramanian,
Professor & Director,
Centre for Materials Joining & Research (CEMAJOR)
Annamalai University, Annamalai Nagar-608002, Tamilnadu.

Dr P Snehalatha,
Associate Professor & Head
Department of Mechanical Engineering,
Sri Padmavathi Mahila Visvavidyalam, Tirupati, Andhra Pradesh-517502, India.

Future Research Plans:

The upcoming work will concentrate on creating Functionally Graded Materials (FGMs) through Wire-Arc Additive Manufacturing (WAAM) by merging nickel and stainless steel. The goal of this research is to leverage the distinct properties of each metal to develop components suited for specialised high-performance applications. The primary challenges involve optimizing the interfaces between materials, refining the deposition processes, and ensuring strong structural integrity throughout the manufacturing process.

The link to the article: https://doi.org/10.1016/j.rineng.2024.102423

Wire Arc Additive Manufacturing (WAAM) is revolutionizing how we make metal components, especially when it comes to materials like 304L austenitic stainless steel—a popular choice in industries such as aerospace, automotive, and healthcare due to its durability and corrosion resistance. The research paper titled “Microstructural Characteristics and Properties of Wire Arc Additive Manufactured 304L Austenitic Stainless Steel Cylindrical Components by Different Arc Welding Processes” published by Dr Maheswar Dwivedy, Associate Professor, Department of Mechanical Engineering and his post-doctoral scholar Dr B Prasanna Nagasai explores this innovative manufacturing method in detail, focusing on how different welding techniques affect the end product.

Overall, this research indicates that WAAM, with its different welding techniques, can produce 304L stainless steel cylinders that potentially outperform those made by conventional forging, both in terms of material efficiency and mechanical properties. Such findings are significant as they point towards more sustainable and cost-effective manufacturing methods that do not sacrifice quality.

Abstract

Wire arc additive manufacturing (WAAM) is an advanced additive manufacturing (AM) technology that offers low cost and high deposition rates, making it suitable for building large metal parts for structural engineering applications. However, various welding procedures result in differing heat inputs and repetitive heating treatments throughout the deposition process, which can affect the microstructural and mechanical characteristics of the parts. In the current study, cylindrical parts made of 304L austenitic stainless steel (ASS) were manufactured using the WAAM technique, employing both gas metal arc welding (GMAW) and cold metal transfer (CMT) processes. This study explores the correlation between WAAM techniques and their effects on the bead geometry, microstructure and mechanical properties. The paper presents detailed analyses of the microstructure using techniques such as optical microscopy, scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS) and X-ray diffraction (XRD). The research findings suggest that the choice of arc welding process significantly affects the grain size, phase distribution, and defect formation within the 304L stainless steel, thereby influencing the mechanical properties and overall performance of the manufactured components. The WAAM-processed 304L ASS cylinders showed better performance compared to those manufactured using traditional industrial forging standards, indicating that WAAM-processed 304L ASS cylinders are suitable for industrial applications. This comprehensive evaluation provides insights into optimising welding processes for enhanced quality and performance of stainless steel cylindrical parts.

Highlights of the research

• Controlling heterogeneous microstructures in WAAM-processed 304L stainless steel is challenging.
• GMAW vs. CMT impacts on 304L ASS microstructure analysed.
• The upward growth of coarse austenite/ferrite morphologies is controlled by the wire retraction mechanism.
• CMT produced finer dendrites and more ferrite morphologies.
• WAAM 304L ASS components outperformed the wrought 304L ASS and forged 304L ASS.

Practical implementation/Social implications of the research

The practical implementation of Wire Arc Additive Manufacturing (WAAM) for 304L austenitic stainless steel could revolutionise multiple industries, including aerospace, automotive, medical devices, maritime, and energy, by allowing the production of complex, custom, and durable components with greater efficiency and reduced material waste. This shift not only promises economic benefits like cost reduction and job creation in advanced manufacturing sectors but also carries significant environmental advantages by minimising waste and the carbon footprint associated with traditional manufacturing processes. Furthermore, the technology enhances supply chain resilience by enabling local, on-demand production, which could be crucial during global disruptions. Socially, WAAM could increase access to customised medical aids in low-income regions, fostering greater equality. The adoption of WAAM thus holds the potential to impact manufacturing practices profoundly, driving innovation, sustainability, and inclusivity across various sectors.

Collaborations

Dr V Balasubramanian, Professor & Director, Centre for Materials Joining & Research (CEMAJOR), Annamalai University, Tamilnadu.

In the future, the research team plan to focus on developing Functionally Graded Materials (FGMs) of nickel and stainless steel using Wire Arc Additive Manufacturing (WAAM). This research will aim to leverage the unique properties of each metal to create components with tailored functional performance for demanding applications. Key challenges will include optimising material interfaces, controlling deposition processes, and ensuring structural integrity.

Read more

The Department of Mechanical Engineering at SRM University-AP is proud to present its research paper titled, Study on Properties and Microstructure of Wire Arc Additive Manufactured 2209 Duplex Stainless Steel by Dr Maheshwar Dwivedy and post-doctoral researcher, Dr B Prasanna Nagasai. Below is a brief write-up on their research.

Abstract:

This study investigates the properties and microstructure of 2209 duplex stainless steel (DSS) components fabricated using the wire arc additive manufacturing (WAAM) technique, specifically employing the gas metal arc welding (GMAW) process. The research focuses on the mechanical properties and microstructural characteristics of the produced cylindrical components. Detailed examination revealed that the microstructure varied from the bottom (region ①) to the top (region ②) of the cylinders, with hardness measurements ranging from 301 HV0.5 to 327 HV0.5, and impact toughness values from 118J to 154J. The tensile properties exhibited anisotropic behavior, with ultimate tensile strength and yield strength ranging from 750 to 790 MPa and 566 to 594 MPa, respectively. The study highlights the significant influence of complex heat cycles and cooling rates on the primary phase balance, resulting in a 50/50 austenite/ferrite distribution. Additionally, σ-phase precipitation was observed at the ferrite grain boundaries. The observed increase in austenite content from region ① to region ② is attributed to reduced cooling rates and extended time for solid-state phase transformation. This research provides valuable insights into optimizing the WAAM process for enhanced performance of 2209 DSS components.

Citation Format:

Prasanna Nagasai, B, Maheshwar Dwivedy, Malarvizhi, S. et al. Study on Properties and Microstructure of Wire Arc Additive Manufactured 2209 Duplex Stainless Steel. Metallogr. Microstruct. Anal. (2024). https://doi.org/10.1007/s13632-024-01089-8

Practical implementation:

The practical implementation of this research on Wire Arc Additive Manufacturing (WAAM) for Duplex Stainless Steel (DSS) has significant implications for industries requiring high-strength, corrosion-resistant components, such as construction, marine, and chemical processing. By optimizing the WAAM process to produce DSS parts with balanced microstructures, manufacturers can create durable and efficient parts more cost-effectively and with less material waste than traditional methods. This advancement could lead to more sustainable manufacturing practices, reducing the environmental impact and operational costs associated with producing large metal components. Socially, the widespread adoption of this technology could drive innovation, create new job opportunities in advanced manufacturing, and contribute to the development of stronger, longer-lasting infrastructure and machinery, ultimately benefiting the economy and society at large.

Collaborations:

Dr V Balasubramanian,
Professor & Director,
Centre for Materials Joining & Research (CEMAJOR)
Annamalai University, Annamalai Nagar-608002, Tamilnadu.

Dr P Snehalatha,
Associate Professor & Head
Department of Mechanical Engineering,
Sri Padmavathi Mahila Visvavidyalam, Tirupati, Andhra Pradesh-517502, India.

Future Research Plans:

In our upcoming work, we will focus on developing Functionally Graded Materials (FGMs) using Wire Arc Additive Manufacturing (WAAM), combining nickel and stainless steel. This research aims to harness the unique properties of each metal to create components tailored for specialized applications requiring high performance. Key challenges include optimizing material interfaces, refining deposition processes, and ensuring robust structural integrity throughout production.

The link to the article– https://doi.org/10.1007/s13632-024-01089-8