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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Table 2 Chemical composition for propeller castings in % Elements Cu [ % ] Al [ % ]

Mn [ % ]

Fe [ % ]

Ni [ % ]

Zn [ % ]Max

Sn [ % ]Max 0.1 0.1- 0.01

Pb [ % ]Max

Ship Rules – IACS W24-CU3 CuAl10Fe5Ni5-C – Casting

77 - 82 7.0 - 11.0

0.5 - 4.0

2.0 - 6.0 4.0-5.5

3.0 - 6.0 4.0-6.0

1.0

0.03 0.03 0.00

Bal

8.5-10.5

3.0

0.50- 0.001

WAAM propeller

81.31

8.70

1.26

3.77

4.80

Table 3 – Mechanical properties for copper alloy propeller castings Properties Rp02 [N/mm2]

UTS [N/mm2]

Elongation [%]

Charpy at 0 Deg C [ J ]

Hardness [ HBW ]

≥ 245 ≥ 250

≥ 590 ≥ 600

≥ 16 ≥ 13

- -

-

Ship Rules – IACS W24-CU3 CuAl10Fe5Ni5 – Casting [30]

≥ 140

W-1 W-2 W3 W4

332 320 329 312

723 702 697 706

21 21 22 19

29 29 29 28

177 173 171

171 The microstructure of the sacrifical propeller blade’s fusion line regions are presented in Figure 4 – 7.

Figure 4. Microsstructure photography of representative

Figure 5. Microsstructure photography of representative

fusion line in test cuopon W1

fusion line in test cuopon W2

Figure 6. Microsstructure photography of representative

Figure 7. Microsstructure photography of representative

fusion line in test cuopon W3

fusion line in test cuopon W4

3.0 DISCUSSION When manufactured by conventional casting, the propeller design must consider the casting process, which encumbers design optimization. Whereas using WAAM, the propeller design optimisation has enhanced flexibility; and potential defects can continuously be detected and rectified during the entire manufacturing process.

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