PSI - Issue 34

Ramesh Babu et al. / Procedia Structural Integrity 34 (2021) 20–25 Ramesh babu/ Structural Integrity Procedia 00 (2019) 000 – 000

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Figure 1. The relation between various variables and the physical properties of weld metal

Figure 2. Illustration of a propeller blade’s Severity zones

2 FULL SCALE WAAM EXPERIMENT For the sake of collecting first-hand WAAM experiences and authentic structural integrity material data one wire arc additive manufactured marine propeller with 2meter dia with thickness 70mm at base to 8mm at tip as shown in figure 3 Right; and one 0.7-meter-long sacrificial propeller blade were constructed by S.Y.Metals. General weld process data is stated in Table 1 based on requirement given by DNV-CP-0267(2018) and DNV-ST-B203(2020) Table 1 General weld process data Base material CU3 -IACS W24 Arc weld machine Fronius CMT welder Arc Weld Process Gas metal arc welding Wire feeder Frontius CMT controller Welding consumable ERCuNiAl Mechanisation Kuka Positioner Shielding Gas Argon (99.99%) Robot control system Kuka Polarity Direct current Data Acquisition system Mobius system Stringer or weave bead Stringer Weld position Flat Min. Preheat temp. 190 °C Max. interpass temp. 250 °C The propeller and sacrificial blade were subjected to Non-Destructive Testing (NDT) in the form of 100% dye penetrant testing; and no flaws were detected. Thereafter, mechanical, and metallurgical test specimens were collected from the sacrificial blade referred in DNV Pt.2 Ch.2 Sec.11(2021) as illustrated in Figure 3 right; test coupons W1 and W3 have weld deposition direction (horizontal) and test coupons W2 and W4 are build direction (vertical). The test specimen locations were selected to represent the high stress and strain magnitude areas at the mid thickness.

Figure 3. Left: WAAM propeller by SYMetal

Right: The test specimens’ location in the sacrificail blade

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