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Aluminium alloy based weld bead modelling for robotic wire + arc additive manufacturing

Pena, Rafael de la (2017). Aluminium alloy based weld bead modelling for robotic wire + arc additive manufacturing. Bachelor of Engineering (4th Year Project) Thesis, Charles Darwin University.

Document type: Thesis
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Author Pena, Rafael de la
Title Aluminium alloy based weld bead modelling for robotic wire + arc additive manufacturing
Institution Charles Darwin University
Publication Date 2017-05
Thesis Type Bachelor of Engineering (4th Year Project)
Supervisor Kannoorpatti, Krishnan
Stefanija, Klaric
Abstract Additive manufacturing is a fabrication process where the component is formed by depositing layers of material on top of one another. This is quite the opposite of traditional subtractive manufacturing where components are formed from an oversized raw material, forming the desired shape of a component involves the removal of unwanted material by means of various machining processes such as milling, shaping, turning and others. For this study, a robotic welder was utilized to perform a WAAM process using aluminium alloy AL 5356 as the filler metal. Bead modelling study begins by examining the single bead profile and determining which of the three empirical models namely parabolic, cosine and arc accurately represents the bead profile. Based on the experimental results and curve fitting method it was verified that the parabolic and arc function closely represents the actual bead profile. Using the data from the single bead experiment, the critical distance was established and was used to construct both the tangent overlapping model and flat overlapping model. From the experimental and curve results, the tangent overlapping model (TOM) shows an accurate approximation of the actual overlapping welds when compared to the flat overlapping model (FOM).

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