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<p>Accurate prediction of single weld bead geometry is essential for ensuring precision and quality in the multi-layer deposition of complex components. This research develops a response surface model to predict bead geometry and explores the microstructures of SS317L single-layer weld beads deposited via the Cold Metal Transfer (CMT) process, with a focus on optimizing welding parameters. Parametric analysis indicated that special CMT mode significantly affected the bead geometry, with wire feed speed (<i>WFS</i>) contributing the highest to bead width (45.36%) and penetration depth (52.52%), while travel speed (<i>TS</i>) was the most influential factor for bead height (57.14%). The genetic algorithm, followed by a novel weighted entropy-based order preference method, yielded the optimal parameters: <i>WFS</i> 3.10&#xa0;m/min, <i>TS</i> 0.17&#xa0;m/min, and standoff distance 22.5&#xa0;mm, for high productivity. Microstructural study revealed that columnar structures grow perpendicular to partially melted grains of the fusion zone, while homogeneous nucleation led to the cellular structures at the weld center. Low heat input (36&#xa0;J/mm) yielded finer structures (10.31 ± 0.42&#xa0;µm) and reduced ferrite content (1.96 ± 0.09%), while high heat input (756&#xa0;J/mm) resulted in coarser structures (17.74 ± 1.28&#xa0;µm) and increased ferrite content (4.12 ± 0.26%). The optimized parameters were finally used for the additive manufacturing of a subscale propeller hub.</p> Graphical abstract <p></p>

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Experimental investigation and microstructural characterization of SS317L single-layer weld beads deposited by the cold metal transfer process

  • 期刊论文

  • 发表日期：

    2025年9月4日

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  • Nitin Patel,
  • Harish Kumar,
  • Sunil Jha

摘要

Accurate prediction of single weld bead geometry is essential for ensuring precision and quality in the multi-layer deposition of complex components. This research develops a response surface model to predict bead geometry and explores the microstructures of SS317L single-layer weld beads deposited via the Cold Metal Transfer (CMT) process, with a focus on optimizing welding parameters. Parametric analysis indicated that special CMT mode significantly affected the bead geometry, with wire feed speed (WFS) contributing the highest to bead width (45.36%) and penetration depth (52.52%), while travel speed (TS) was the most influential factor for bead height (57.14%). The genetic algorithm, followed by a novel weighted entropy-based order preference method, yielded the optimal parameters: WFS 3.10 m/min, TS 0.17 m/min, and standoff distance 22.5 mm, for high productivity. Microstructural study revealed that columnar structures grow perpendicular to partially melted grains of the fusion zone, while homogeneous nucleation led to the cellular structures at the weld center. Low heat input (36 J/mm) yielded finer structures (10.31 ± 0.42 µm) and reduced ferrite content (1.96 ± 0.09%), while high heat input (756 J/mm) resulted in coarser structures (17.74 ± 1.28 µm) and increased ferrite content (4.12 ± 0.26%). The optimized parameters were finally used for the additive manufacturing of a subscale propeller hub.

Graphical abstract