FARKLI MALZEME KATMANLI ÜRÜNLERİN TEL ARK EKLEMELİ İMALATI
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2022-03
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info:eu-repo/semantics/openAccess
Özet
Fonksiyonel derecelendirilmiş malzemeler (FDM) farklı malzeme özelliklerini tek bir yapıda sağlayabilen üretimlerdir. Endüstride farklı amaçlar için kullanılan parçalardan kimi zaman bölgesel olarak farklı malzeme davranışlarını sergilemesi istenebilmektedir. Bu tür ihtiyaçlarda FDM yapılarının kullanılması bir çözüm olarak ortaya çıkmaktadır. FDM yapılarının geleneksel imalat yöntemleriyle üretilmesi ise genel olarak zor olup, bazen mümkün olamamaktadır. Ancak günümüzde birçok kullanıma ve araştırmalara konu olan eklemeli imalat (Eİ) tekniği, sunduğu avantajlar sayesinde FDM yapılarının üretimi noktasında geleneksel yöntemlere göre üstün bir imalat yöntemi olmuştur. Eİ yöntemiyle katman şeklinde üretim yapılabilmesi, katman özellikleri değiştirilebilen yapıların imalatına izin vermektedir. Bu çalışma metal Eİ tekniklerinden biri olan tel ark eklemeli imalat (TAEİ) yöntemiyle FDM yapılarının üretilmesi üzerine gerçekleşmiştir. FDM yapılarında iki farklı kimyasal bileşime sahip düşük alaşımlı çelik (SG2) ile östenitik paslanmaz çelik (308LSi) metal teller kullanılmıştır. TAEİ işlemleri çalışmalar kapsamında özel olarak tasarlanan ve gelişmiş özellikler kazandırılan bir tezgahın üretimiyle gerçekleştirilmiştir. Malzeme yığma işlemlerinde MIG/MAG kaynak yöntemi tercih edilmiştir. Üretim işlemleri temel olarak iki farklı düzende uygulanmıştır. Bunlardan ilki sadece tek besleyici tel ile üretilen tek malzemeli yapıları diğeri ise farklı iki tel kullanımıyla FDM yapılı üretimleri kapsamaktadır. Toplamda 4 farklı üretim gerçekleştirilmiş, bunlardan 1’incisi tamamı sadece SG2, 2’ncisi ise tamamı sadece 308LSi tel malzemesinden oluşacak şekilde üretilmiştir. 3’üncüsü yarısı SG2 diğer yarısı 308LSi malzemesinden oluşacak şekilde üretilmiştir. 4’üncüsü SG2 ve 308LSi malzemelerinin her katmanda sırasıyla değiştirilmesi şeklinde üretilmiştir. 4 farklı üretim grubunun elde edilmesinden sonra tek malzemeli ve FDM yapılarının özelliklerini belirlemek için birçok mekanik ve metalürjik testler uygulanmıştır. Mekanik özellikleri belirlemede, sertlik, çekme, yorulma, eğme ve çentik darbe testleri, metalurjik özellikler için ise makro/mikro yapı çalışmaları yapılmıştır. Tüm üretim gruplarına uygulanan deneysel çalışmalarda elde edilen bulgular birbiriyle mukayese edilmiştir. Deneysel çalışmalar sonucunda FDM üretimlerinin hiçbirinde üretim hatasıyla karşılaşılmamış ve FDM yapılarında bulunan iki farklı malzemeden dolayı meydana gelen ara yüzeyler tüm testlerden başarılı olmuştur. FDM üretimiyle tek malzemeli üretimlere göre üstün mekanik özellikler sağlanmıştır. FDM yapılarında tek malzemeli üretimlerle kıyaslandığında; çekme dayanımında % 50’ye, yorulma dayanımında ise % 34’e varan artış tespit edilmiştir. Çalışmalar sonucunda TAEİ yöntemiyle özellikleri üstün FDM yapılarının üretilebileceği görülmüştür.
Functionally graded materials (FGM) are components that can provide different material properties in a single structure. It is sometimes required to exhibit locally different material behaviors from parts used for various purposes in the industry. In such requirements, the use of FGM structures emerges as a solution. The production of FGM structures with traditional manufacturing methods is generally difficult and sometimes not possible. However, the additive manufacturing (AM) technique, which is the topic of many applications and research today, has emerged as a superior manufacturing method compared to traditional methods in producing FGM structures, thanks to its advantages. Fabrication in the form of layers with the AM method allows the manufacture of components whose layer properties can be changed. This study was carried out on the fabrication of FGM structures by the wire arc additive manufacturing (WAAM) method, which is one of the metal AM techniques. Low alloy steel (SG2: ER70S-6) and austenitic stainless steel (308LSi) metal wires with two different chemical compositions are used in FGM structures. WAAM process was carried out by producing a specially designed machine with advanced features within the studies. MIG/MAG welding method was chosen for material deposition processes. The fabrication procedures were carried out in two different orders. The first of these contains single-material structures produced with only one metal wire, and the other includes FGM-structured fabrications using two different wires. In total, four different fabrications were carried out, the first of which was made entirely of only SG2, and the second was made completely of only 308LSi wire material. The third half is made of SG2, and the other half is made of 308LSi material. The fourth is manufactured by replacing the SG2 and 308LSi materials in each layer. After obtaining four different fabrications, mechanical and metallurgical tests were applied to determine the properties of single-material and FGM structures. Hardness, tensile, fatigue, bending and notch impact tests were applied to determine the mechanical properties. Macrostructure and microstructure studies were carried out to assess metallurgical properties. After completing the experimental studies, the results of all fabrications were compared with each other. As a result of the tests applied, no manufacturing defect was encountered in any of the FGM parts, and the interfaces of two different materials in the FGM parts were successful in all tests. With FGM fabrication, superior mechanical properties are provided compared to single-material constructions. Compared to single-material productions in FGM structures, an increase of 50% in tensile strength and up to 34% in fatigue strength was detected. At the end of the study, it was seen that FGM structures with superior properties could be fabricated with the WAAM method."
Functionally graded materials (FGM) are components that can provide different material properties in a single structure. It is sometimes required to exhibit locally different material behaviors from parts used for various purposes in the industry. In such requirements, the use of FGM structures emerges as a solution. The production of FGM structures with traditional manufacturing methods is generally difficult and sometimes not possible. However, the additive manufacturing (AM) technique, which is the topic of many applications and research today, has emerged as a superior manufacturing method compared to traditional methods in producing FGM structures, thanks to its advantages. Fabrication in the form of layers with the AM method allows the manufacture of components whose layer properties can be changed. This study was carried out on the fabrication of FGM structures by the wire arc additive manufacturing (WAAM) method, which is one of the metal AM techniques. Low alloy steel (SG2: ER70S-6) and austenitic stainless steel (308LSi) metal wires with two different chemical compositions are used in FGM structures. WAAM process was carried out by producing a specially designed machine with advanced features within the studies. MIG/MAG welding method was chosen for material deposition processes. The fabrication procedures were carried out in two different orders. The first of these contains single-material structures produced with only one metal wire, and the other includes FGM-structured fabrications using two different wires. In total, four different fabrications were carried out, the first of which was made entirely of only SG2, and the second was made completely of only 308LSi wire material. The third half is made of SG2, and the other half is made of 308LSi material. The fourth is manufactured by replacing the SG2 and 308LSi materials in each layer. After obtaining four different fabrications, mechanical and metallurgical tests were applied to determine the properties of single-material and FGM structures. Hardness, tensile, fatigue, bending and notch impact tests were applied to determine the mechanical properties. Macrostructure and microstructure studies were carried out to assess metallurgical properties. After completing the experimental studies, the results of all fabrications were compared with each other. As a result of the tests applied, no manufacturing defect was encountered in any of the FGM parts, and the interfaces of two different materials in the FGM parts were successful in all tests. With FGM fabrication, superior mechanical properties are provided compared to single-material constructions. Compared to single-material productions in FGM structures, an increase of 50% in tensile strength and up to 34% in fatigue strength was detected. At the end of the study, it was seen that FGM structures with superior properties could be fabricated with the WAAM method."
Açıklama
Anahtar Kelimeler
Eklemeli imalat, tel ark eklemeli imalat, fonksiyonel derecelendirilmiş malzemeler, MIG/MAG kaynağı, nitelikli ürünler., Additive manufacturing, wire arc additive manufacturing, functionally graded materials, MIG/MAG welding, functional products.