SpringerLink
Log in

Optimization of parameters of micro-plasma transferred arc additive manufacturing process using real coded genetic algorithm

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Micro-plasma transferred arc additive manufacturing (μ-PTAAM) process developed at IIT Indore has proven be an energy and material efficient additive manufacturing process for various meso-scale ALM applications of high melting point metallic materials. This paper reports on optimization of three most important parameters (i.e. micro-plasma power, worktable travel rate and wire feed rate) of μ-PTAAM process by real coded genetic algorithms so as to minimize the aspect ratio (i.e. ratio of deposition width to deposition height) with an overall objective to increase productivity of this process. Objective function for aspect ratio was formulated using generic theoretical thermal developed in terms of μ-PTAAM process parameters and properties of the substrate and deposition material and models developed using regression analysis and artificial neural networks (ANN). It gave optimized values of micro-plasma power as 370, 355 and 360 W, respectively, by the thermal model, regression model and ANN model, and that of travel speed of worktable and wire feed rate as 100 mm/min and as 1700 mm/min by all three models. The optimized results were validated experimentally by depositing 0.3-mm diameter wire of P20 on 5-mm-thick substrate of the same material. The optimized values of the aspect ratio using objective function based generic thermal model, regression model and ANN model are 1.15, 1.31 and 1.36, respectively, with corresponding experimental values being 1.48, 1.5 and 1.48, respectively. Use of optimum process parameters resulted in very good quality and accuracy of the deposition which has excellent bonding with the substrate material and no internal defects.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Subscribe and save

Springer+ Basic
EUR 32.99 /Month
  • Get 10 units per month
  • Download Article/Chapter or Ebook
  • 1 Unit = 1 Article or 1 Chapter
  • Cancel anytime
Subscribe now

Buy Now

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10

Similar content being viewed by others

Abbreviations

AR :

Aspect ratio of deposition geometry

A w :

Cross-section area of the deposition material (mm2)

C d :

Specific heat of the deposition material (J/Kg K)

C s :

Specific heat of the substrate material (J/Kg K)

D :

Dilution i.e. ratio of deposited area to sum of deposited and diluted area (%)

f w :

Wire feed rate (mm/s)

F AR :

Fitness value of aspect ratio

h :

Height of the deposition (mm)

P :

Micro-plasma power (W)

T i :

Ambient temperature (K)

T md :

Melting temperature of the deposition material (K)

T ms :

Melting temperature of the substrate material (K)

v :

Travel speed of worktable (mm/s)

w :

Width of the deposition (mm)

α s :

Thermal diffusivity of the substrate material (mm2/s)

Ƞ :

Thermal efficiency of micro-plasma transferred arc (%)

ρ d :

Density of the deposition material (kg/mm3)

ρ s :

Density of the substrate material (kg/mm3)

References

  1. Jhavar S, Jain NK, Paul CP (2014) Development of micro-plasma transferred arc (μ-PTA) wire deposition process for additive layer manufacturing applications. J Mater Process Technol 214(5):1102–1110. https://doi.org/10.1016/j.jmatprotec.2013.12.016

    Article  Google Scholar 

  2. Sawant MS, Jain NK (2018) Investigations on Additive Manufacturing of Ti-6Al-4V by μ-Plasma Transferred Arc Powder Deposition Process. Trans ASME: J Manuf Sci Engg 140(8):081014-1–081014-11. https://doi.org/10.1115/1.4040324

    Article  Google Scholar 

  3. Nikam SH, Jain NK (2019) Modeling and Prediction of Residual Stresses in Additive Layer Manufacturing by Microplasma Transferred Arc Process Using Finite Element Simulation. Trans ASME: J Manuf Sci Engg 141(6):061003-1–061003-14. https://doi.org/10.1115/1.4043264

    Article  Google Scholar 

  4. Nikam SH, Jain NK (2018) 3D-finite element simulation and image processing based prediction of width and height of single-layer deposition by micro-plasma-transferred arc process. Int J Adv Manuf Technol 95(9–12):3679–3691. https://doi.org/10.1007/s00170-017-1472-x

    Article  Google Scholar 

  5. Lestan Z, Klancnik S, Balic J, Brezocnik M (2015) Modeling and design of experiments of laser cladding process by genetic programming and nondominated sorting. Mater Manuf Process 30(4):458–463. https://doi.org/10.1080/10426914.2014.973586

    Article  Google Scholar 

  6. Yanxi Z, **angdong G, Seiji K (2015) Weld appearance prediction with BP neural network improved by genetic algorithm during disk laser welding. J Manuf Syst 34(C):53–59. https://doi.org/10.1016/j.jmsy.2014.10.005

    Article  Google Scholar 

  7. Verma A, Rai R (2016) Sustainability-induced dual-level optimization of additive manufacturing process. Int J Adv Manuf Technol 88(5–8):1945–1959. https://doi.org/10.1007/s00170-016-8905-9

    Article  Google Scholar 

  8. Dey V, Pratihar DK, Datta GL, Jha MN, Saha TK, Bapat AV (2010) Optimization and prediction of weldment profile in bead-on-plate welding of Al-1100 plates using electron beam. Int J Adv Manuf Technol, 48(5–8):513–528. DOI:https://doi.org/10.1007/s00170-009-2307-1, 528

    Article  Google Scholar 

  9. Siva K, Murugan N, Logesh R (2009) Optimization of weld bead geometry in plasma transferred arc hardfaced austenitic stainless steel plates using genetic algorithm. Int J Adv Manuf Technol 41:24–30. https://doi.org/10.1007/s00170-008-1451-3

    Article  Google Scholar 

  10. Kim D, Rhee S (2001) Optimization of arc welding process using a genetic algorithm. Weld J Res Suppl 184–189

  11. **ong J, Zhang G, Hu J, Wu L (2014) Bead geometry prediction for robotic GMAW-based rapid manufacturing through a neural network and a second-order regression analysis. J Intell Manuf 25(1):157–163. https://doi.org/10.1007/s10845-012-0682-1

    Article  Google Scholar 

  12. Senthilkumar B, Kannan T, Madesh R (2015) Optimization of flux-cored arc welding process parameters by using genetic algorithm. Int J Adv Manuf Technol 93(1–4):35–41. https://doi.org/10.1007/s00170-015-7636-7

    Article  Google Scholar 

  13. Lin HL (2012) The use of the Taguchi method with grey relational analysis and a neural network to optimize a novel GMA welding process. J Intell Manuf 23(5):1671–1680. https://doi.org/10.1007/s10845-010-0468-2

    Article  Google Scholar 

  14. Datta S, Bandyopadhyay A, Pal PK (2008) Grey-based taguchi method for optimization of bead geometry in submerged arc bead-on-plate welding. Int J Adv Manuf Technol 39:1136–1143. https://doi.org/10.1007/s00170-007-1283-6

    Article  Google Scholar 

  15. Nagaraju S, Vasantharaja P, Chandrasekhar N, Vasudevan M, Jayakumar T (2016) Optimization of welding process parameters for 9Cr-1Mo steel using RSM and GA. Mater Manuf Process 31(3):319–327. https://doi.org/10.1080/10426914.2015.1025974

    Article  Google Scholar 

  16. Da Silva MM, Batista VR, Maciel TM, Dos Santos MA, Brasileiro TL (2018) Optimization of submerged arc welding process parameters for overlay welding. Weld Int 32(2):122–129. https://doi.org/10.1080/09507116.2017.1347325

    Article  Google Scholar 

  17. Vimal KEK, Vinodh S, Raja A (2017) Optimization of process parameters of SMAW process using NN-FGRA from the sustainability view point. J Intell Manuf 28(6):1459–1480. https://doi.org/10.1007/s10845-015-1061-5

    Article  Google Scholar 

  18. Chaki S, Shanmugarajan B, Ghosal S, Padmanabham G (2015) Application of integrated soft computing techniques for optimisation of hybrid CO2 laser-MIG welding process. Appl Soft Comput 30:365–374. https://doi.org/10.1016/j.asoc.2015.01.045

    Article  Google Scholar 

  19. Orishich AM, Malikov AG, Shelyagin VD, Khaskin VY, Chayka AA (2016) Optimisation of the processes of laser, microplasma and hybrid laser–microplasma welding of aluminium alloys. Weld Int 30(12):957–961. https://doi.org/10.1080/09507116.2016.1157338

    Article  Google Scholar 

  20. Jhavar S, Paul CP, Jain NK (2016) Micro-plasma transferred arc additive manufacturing for die and mold surface remanufacturing. JOM: J Mine Meta Mater Soc 68(7):1801–1809. https://doi.org/10.1007/s11837-016-1932-z

    Article  Google Scholar 

  21. Nikam SH, Jain NK, Jhavar S (2016) Thermal modeling of geometry of single-track deposition in micro-plasma transferred arc deposition process. J Mater Process Technol 230:121–130. https://doi.org/10.1016/j.jmatprotec.2015.11.022

    Article  Google Scholar 

  22. Kim D, Rhee S, Park H (2002) Modelling and optimization of a GMA welding process by genetic algorithm and response surface methodology. Int J Prod Res 40(7):1699–1711. https://doi.org/10.1080/00207540110119964

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. School of Computing, Engineering and Intelligent Systems, Ulster University, Derry/Londonderry, BT48 7JL, Northern Ireland, UK

    Sagar H. Nikam

  2. Discipline of Mechanical Engineering, Indian Institute of Technology Indore, Simrol, MP, 453 552, India

    Neelesh Kumar Jain & Mayur S. Sawant

Authors
  1. Sagar H. Nikam
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Neelesh Kumar Jain
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Mayur S. Sawant
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Neelesh Kumar Jain.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Nikam, S.H., Jain, N.K. & Sawant, M.S. Optimization of parameters of micro-plasma transferred arc additive manufacturing process using real coded genetic algorithm. Int J Adv Manuf Technol 106, 1239–1252 (2020). https://doi.org/10.1007/s00170-019-04658-2

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-019-04658-2

Keywords

Search

Navigation