Akademik Veri Yönetim Sistemi
Progress in Additive Manufacturing, cilt.10, sa.11, ss.9355-9370, 2025 (ESCI, Scopus)
Wire-arc additive manufacturing (WAAM) has gained increasing prominence in aerospace applications due to its ability to produce lightweight, complex components with reduced lead times. Its key advantage lies in minimizing material waste and scrap, making it especially suitable for high-value aerospace parts. This study explores the fabrication of load-bearing cylindrical rods, critical for topologically optimized designs, using a dot-by-dot WAAM approach. By constructing cylindrical wireframe structures, this method achieves significant weight reduction while maintaining structural integrity. The optimization of welding parameters, a crucial factor in WAAM, is systematically addressed through a design of experiments methodology. Initial trials assess how variations in welding parameters influence product quality, with both destructive and non-destructive tests conducted to evaluate performance. The resulting microstructure, layer thickness, and column diameters under different parameter sets are meticulously documented, providing valuable insights for design applications. Furthermore, the ability to achieve a smooth gradient in parameter adjustments across varying thickness regions is emphasized, highlighting its importance in the production of topologically optimized parts. The microstructural analysis revealed a predominantly dendritic structure with low melting point segregations in the pulse multi-control (PMC) approach, with no insufficient melting between interlayers and pores compared to cold metal transfer (CMT) approach. X-ray images confirmed a lower porosity in the PMC mode compared to CMT synergetic mode, supporting the mechanical test findings. Tensile tests showed that rods manufactured with optimized PMC parameters exhibited ultimate tensile strength values up to 187 MPa and elongation percentages reaching 4.9%. These improvements indicate that PMC welding parameters significantly influence the quality and reliability of dot-by-dot WAAM rods.