Affiliation:
1. Additive Manufacturing Research Group, CSIR—Central Mechanical Engineering Research Institute 1 , Durgapur 713209, India
2. Academy of Scientific and Innovative Research (AcSIR) 2 , Sector 19, Kamla Nehru Nagar, Ghaziabad, Uttar Pradesh 201002, India
Abstract
Cemented carbide (WC-Co), the widely used tool-die material, is difficult to be machined by conventional and nonconventional techniques. This inspired exploring additive manufacturing (AM) of this material. However, porosity, brittleness due to cobalt depletion, etc. have been reported in the literature with rare success. For the AM of WC-Co, the current work focuses on directed energy deposition, which can be implemented with existing laser cutting-welding workstations, with modifications. To ensure the retention of cobalt even after inevitable vaporization of some of its initial content during deposition, 20 wt. % of Co was mixed with WC powder by low-energy ball milling. Laser power, scan speed, and powder flow rate were varied following a full-factorial design of experiments. The analysis of variance revealed that the experimental model and most of the parameters were significant. Only the laser power came out to be insignificant for the contact angle. The track height and width increased with the laser power and reduced with the scan speed. The contact angle increased with the scan speed and reduced with the powder flow rate. Cross sections of the deposited track showed no pores or cracks. Multiobjective optimization with gray relational analysis was conducted to get the parameter combination giving high values of the contact angle, track height, and width simultaneously. The optimum parameter combination, thus, obtained is 700 W laser power, 5 mm/s scan speed, and 5 g/min powder flow rate. This yielded 305 ± 40 μm track height, 2132 ± 33 μm width, and 152° ± 2° contact angle.
Funder
Department of Science and Technology, Ministry of Science and Technology, India
Publisher
Laser Institute of America
Subject
Instrumentation,Biomedical Engineering,Atomic and Molecular Physics, and Optics,Electronic, Optical and Magnetic Materials