Title: The effects of machining on material properties in hybrid welding/milling based rapid prototyping

Authors: Mohammad Pervez Mughal, Rizwan A. Mufti, Hassan Fawad

Addresses: University of Engineering and Technology, Lahore, Pakistan. ' GIK Institute of Engineering Sciences and Technology, Topi, NWFP, Pakistan. ' GIK Institute of Engineering Sciences and Technology, Topi, NWFP, Pakistan

Abstract: Rapid Prototyping (RP) or Solid Freeform Fabrication (SFF) is one of the fastest developing automated manufacturing technologies in which CAD models can be directly used to make finished products. A welding based RP process shows good promise to produce dense, and structurally strong metallic parts and tools. In this paper a comparison of the material properties is made between weld based prototype parts, produced both with and without intermediate machining after each deposited layer. Material properties were investigated both on a macro and microscopic level. It has been found that there exists a sequential fluctuating behaviour in the microstructure of the deposit without machining. This behaviour, however, is only confined to the top layer of the Deposition with Intermediate Machining (DWIM). The hardness test results also reveal a similar behaviour. Tensile testing results on the contrary show little difference in the strength of the two types of buildups.

Keywords: RP; rapid prototyping; milling; GMAW; gas metal arc welding; microstructure; solid freeform fabrication; SFF; material properties; microstructure; deposition; intermediate machining; hardness testing; tensile testing.

DOI: 10.1504/IJCMSSE.2009.024920

International Journal of Computational Materials Science and Surface Engineering, 2009 Vol.2 No.1/2, pp.3 - 17

Published online: 04 May 2009 *

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