QUALITY IMPROVEMENT OF SHAPED METAL DEPOSITED COMPONENTS USING NON-TRADITIONAL TECHNIQUES: A REVIEW

International Journal of Mechanical and Production Engineering Research and Development (IJMPERD) ISSN (P): 2249–6890; ISSN (E): 2249–8001 Vol. 10, Issue 3, Jun 2020, 2411–2430 © TJPR Pvt. Ltd.

QUALITY IMPROVEMENT OF SHAPED METAL DEPOSITED COMPONENTS USING NON-TRADITIONAL TECHNIQUES: A REVIEW ADNAN A. UGLA*, DHUHA J. KAMIL & HASSAN J. KHAUDAIR Mechanical Engineering Department, College of Engineering, University of Thi-Qar, Al- Nassyriah, Iraq ABSTRACT Shaped Metal Deposition (SMD) is an innovative manufacturing procedure, its an additive layers manufacturing technique offers a fast, multipurpose, and cost-effective substitute for the traditional manufacturing techniques, and is ideal for the production of short-runs of parts, mass customization, or a one-off repair solution and used for manufacturing large, expensive metal components with complex geometry in addition to fabricating free structures by construction materials in a layer by layer technique. This paper aims to comprehensively review the most prominent facts that researchers have dealt with in the SMD techniquesespecially those associated with the grain refinement features used in the SMD process. This study intends to review the literature presented on metal deposition processes and its advantages, including SMD process usingWire + Arc Additive Manufacturing (WAAM) which divides intowire + tungsten inert gas (TIG), metal inert gas (MIG), DW-SMD process. This literary research focuses on the refinement of in the SMD process. Furthermore, maybe done using Single Wire-MIG (SW-MIG) welding and SMD using Double Wire-MIG (DWMIG) welding. The present review shows that the method ofusing ultrasonic vibration and pulsing current can beconsidered a distinctive and low-cost method to produce enhanced components with high mechanical properties.

KEYWORDS: Shaped Metal Deposition, Ultrasonic Vibration, Pulse Current Shaped Metal Deposition, Double-Wire

Original Article

grains and mechanical properties by the usage of ultrasonic vibration and the pulse current inMIG and Tandem-MIG

Feed & Cold Feed Wire

Received: Jun 06, 2020; Accepted: Jun 26, 2020; Published: Jul 07, 2020; Paper Id.: IJMPERDJUN2020224

1. INTRODUCTION Shaped Metal Deposition methodsSMD is an innovative manufacturing procedure that produced by Rolls-Royce PLC and certified by the University of Sheffield [1]. SMD allows difficult metal parts to be instantly produced from a CAD model. SMD offers a fast, versatile, and cost-effective substitute for the traditional manufacturing techniques, and is ideal for the production of short-runs of parts, mass customization, or a one-off repair solution [1].

SMD process is conducted by externally supplying a cold wire of metallic material into a weld pool layer by layer to be able to gain a designed element form [2, 3]. SMD can be viewed as a net or a near net-shaped part manufacturing process when compared with the modern AM techniques. The SMD process creates completely thick components and guarantees outstanding benefits of using any welded materials which are hard-to-machine and to make alloys. However, it ought to be clear that the microstructure of the SMD components comparing with deposited parts is different by the large temperature ranges and the high cooling rates [4-6].

The most positive aspects of the SMD process are defined whenever components are made from high-cost

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materials such as titanium. Titanium is popular within commercial industries such as aviation, medical, sporting activities, automobiles, and also naval. The actual most preferred titanium alloys are Ti-6Al-4V, which accounts for 60% of titanium production [2, 7, 8]. The SMD method can be more useful components produced from expensive alloys such as Ti-6Al-4V, Inconel 718, and TiAl [9,10]. Up to now, to be able to acquire a desired final shape, the standard production techniques, such as machining, are in line with the materials getting rid of the workpiece. There are many obvious disadvantages with this procedure, such as the big waste associated with the material in scraps and the consequent increase in the costs, to the materials utilized. Hensinger et al. [11] Find out that the process can produce parts using a wide variety of materials including stainless steel alloys, titanium alloys, and tool steel alloys. The deposited material shows exceptional material properties appropriate to the parent material. adding the deposited materials have fairly small metallic grain sizes, a property that enhances wear resistance. Ultimately, microstructure assessment related to producing segments affirms that one will discover no disadvantages from the top quality perspective [4]. This process can be used especially for the rapid manufacture of metal components where there are no additional tools available [2, 12]. However, it should be clear that the microstructure of SMD components differs from those prepared with traditional techniques since then The SMD process repeatedly subject to high temperatures and high cooling rates Deposited components, may lead to anisotropic phenomenon [4, 13]. SMD components may have some superconductive characteristics compared to the same casting design components. Casting components have a weight penalty because of their less consistent mechanical properties while SMD components have internal potential to overcome polycrystalline castings of the same chemistry due to more uniform solidification conditions, this is made possible by the deposition process compared to the solidification conditions in casting processes, strength and pressure at the ultimate values of SMD components result in slightly higher than the cast materials [4, 14]. The mechanical properties of a component produced by an SMD process (WAAM or DMD) varies greatly according to deposition parameters, such as plasma arc Power, speed, wire feeding, etc. Generally, the mechanical properties of deposited Parts are competitive and may even have the characteristics of wrought materials and they may possess some desirable properties suitable for the aerospace industries [15]. Overall, the SMD group of AM operations provides high flexibility and costeffectiveness alternatives to traditional manufacturing methods for both mass production-time prototype creations [16, 17].

It is expected that the SMD process has a major influence on design changes and the production of large dense parts and it can be considered as a repair tool method to be used for high-performance alloy components such as metal dies across a broad market [18]. Also, this process promises to produce large scale and high-quality parts with very high deposition rates [19, 20]. SMD technologies have been presented to the aerospace manufacturing industry as a unique low-cost solution to manufacturing large structural components due to its high deposition rate and efficiency. These technologies can greatly improve product development time, capital investment, and BTF ratios [3]. The key positive viewpoints and restrains concerning SMD techniques could be outlined as: 

Depositing procedure using WAAM systems can be accomplished using chamber or outside the chamber just as that you don't have a vacuum situation, for example, in the EBM process [21, 22].



SMD is perfect for complete robotization [2, 4, 23].



High depositing rates, low-cost components, as well as much less time associated with the manufacturing process because of the reduced amount in cooling time [3, 24].



It can manufacture large structural segments, particularly for the aeronautics and defense industry parts [3, 12].

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It may achieve substantial interest in the real current times because of its higher depositing rates as well as more notable effectiveness [25, 26].



It typically requires, additional machining procedures to gain a much better surface [27].



The WAAM techniques can't be used to create Small components and multifaceted section geometries [28].



The present work aims to comprehensively review the most prominent facts that researchers have dealt with in the SMD techniques especially those associated with the grain refinement features used in the SMD process.

2. SMD USING WIRE AND ARC ADDITIVE MANUFACTURING (WAAM) WAAM systems offer brand new paths to create a final form of metal components. WAAM indicates the switching stage within the metal AM systems because it brings together the electrical arc heat sources with a metal wire for the system to produce 3D metallic parts by depositing beads of weld metal in a layer by layer[1].

WAAM process can be classified into three strategies based on the type of electric arc torch used to melt the filler wire: (i) 3D-TIG welding process (TIG or GTAW + wire feedstock) Yilmazand Ugla [29, 30], (ii) 3D-MIG welding process (MIG or GMAW + wire feedstock) [31, 32], Knezović et al.[33],and Dos Santos et al.[32] and (iii) 3D-Plasma Welding process (Plasma + wire feedstock) [34] and Sawant et al. [35]as shown in figure (1).

Within the GMAW, electric arc welding is created from two poles, one of which is the consumable wire electrode and the other is from a workpiece metal. The wire is generally perpendicular to the substrate. a modified GMAW variant depended on a controlled dip transfer mode mechanism, which has already been used concerning AM procedures [26, 36], due to its high deposition rate and low heat input.

GTAW and PAW exploited a non-consumable tungsten electrode to create the weld as shown in figure (1) different in GMAW, the wire feed orientation in GTAW and PAW is various and has an effect on the grade of the deposit, which makes the process arranging more difficult. The contemporary automation technique enables high geometric flexibility.

Using the local protecting method, extremely reactive metallic elements could be created within an out-of-chamber atmosphere [36].

Different components may be utilized in the WAAM process, like steel, aluminum alloy, and titanium alloy.

Mehnen et al. [37] discussed the design of the WAAM process, in specific, the non-traditional stiffeners design as shown in figure (2). A study is presented with different designs of stiffeners to determine the finest structures. Different construction techniques have been explored via experiments.

The current study reviewed by the researchers who used the SMD method in the different conventional methods of GMAW, Single Wire-GMAW (SW-GMAW), Double Wire-GMAW (DW-GMAW).

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Figure 1: Schematic Diagram of the (a) GMAW, (b) GTAW, and (c) PAW Process [23].

Figure 2: WAAM Components: (a) Mild Steel Honeycomb Structure; (b) Aluminum Stiffened Panel Structure; (c) 1-Meter Long Ti64 Wall Structure [37].

3. SMD USING SINGLE WIRE-GMAW (SW-GMAW) The gas metal arc welding GMAW is a widespread electric arc depended on the SMD technique. GMAW is also known as the MIG welding process. SW-GMAW (convention MIG welding) applies to the actual consumable wire as the electrode creating an electric arc for depositing the metal layers as shown in figure (3) [38]. The actual angle between torch arc and the substrate often is 90 degrees.

A deposition of a material using SW-GMAW is accomplished by an automatic robot controller. Several types of research on the GMAW-based AM have been explored. Some of them applied a metal transfer control method to manipulate the size and frequency of the droplets to be able to enhance the deposition accuracy utilizing SW-GMAW [39].

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Figure Error! No text of specified style in document.3: Schematic of GMAW [87].

Xiong et al.[40] specified that the bead thickness within the multilayer depositing process may be held consistent to enhance the dimensional precision resulting in reducing the waste material and energy by modifying the deposition velocity under a passive vision sensor system using the SW-GMAW technique.

GMAW mainly owns the benefit of higher travel speed, less distortion, higher deposition rate, and higher quality of deposited welded parts. Nevertheless, the high spatter rate comparable with the GTAW technique is one of the matters to solve [41].

Some researchers in the field of Pulse-GMAW (P-GMAW) and fluctuating current gas metal arc welding (ACGMAW) developed many types of research and studies in this area are reviewed in [42, 43].

Also, there are many types of research in the field of Pulse-GMAW and Pulse-GTAW which are reviewed in [30, 44, 45].

GMAW, there are many researchers have used the DW-GMAW which will be discussed in the next section.

4. SMD USING DOUBLE WIRE-GMAW (DW-GMAW) To resolve distortions and crack problem and find a way to noticeably increase the productivity and reduce the heat input, two technologies have been generated to modify GMAW for faster deposition: Tandem-GMAW [43, 46], Variable-Polarity GMAW (VP-GMAW) [43]. (DW)-MIG-SMD [47] Variants of cold metal transfer include CMT pulse (CMT-P), CMT advanced (CMT-ADV), and CMT pulse advanced (CMT-PADV), which have been developed by Fronius [48]. Cold metal transfer (CMT) is widely accepted as the most reliable variant to process Al alloys. However, CMT pulse advanced (CMTPADV), developed by Fronius, and was proven to eliminate gas pores, due to an oxide cleaning effect [48] MIG-welding plus cold passed on 3D shaped metal deposition (SMD) is comparatively new technologies for additive manufactured parts. consistsof MIG-welding plus cold wire feed and 3-axismachine to be able to apply the deposition process paths as shown in figure (4).Ugla et al.[47]investigated(DW)-MIG-SMD technique and it has been found from the outcomes of the conducted experiments that the wire feed ratio significantly affects the quality of the deposited parts, this parameter is counted as a new addition to the shaped metal deposition technique using the 3D-SMD plus a cold wire feed. www.tjprc.org

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Figure Error! No text of specified style in document.4: Schemes Illustrate the External Cold Wire Feed Plus MIG-Welding of SMD System.

Tandem-DE-GMAW, a good innovation recognized as consumable double-wire GMAW (DW-GMAW) and called double-electrode GMAW, has been established at the University of Kentucky. In Tandem GMAW, a couple of torches are integrated into one large torch, and a pair of shuts arcs are usually separately proven between their wire and workpiece in parallel and are modified by their own GMAW power source as shown in figure (5).

Figure Error! No text of specified style in document.5: Schematic Illustrates Rig Used for Evaluating the Tandem Pulsed GMAW Arcs [102]. to increase the deposition rate, the speed of production, and obtaining parts with a good surface finish DW-GMAW is used. Pires et al. [49] compared the DW-GMAW technique with pulse-GMAW and conventional GMAW technique and detailed a few benefits like a varied modifying range, The ability to control all weld positions, Control the settings of the control system, decreasing the overall heat input, enhancing combined properties, Powerful weld pool,decreased crack sensitivity.

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Some of the research discussed the problems of the arrangement of the double wires, the selection of welding currents and wire feed rates with a couple of wires that effect on weld bead formation through the tandem pulsed MIG welding technique, in which two wires are fed with pulsed welding currents supplied individually, to be able to explain the essential requirements for sound weld beads without undercut and humping in the higher speed welding of steel sheets [99].

Besides that, some researchers have been able to combine the two GMAW-torch and GTAW-torch to minimize the heat input of the base metal. Li et al.[50] suggested the DE-GMAW a variation of conventional GMAW for reduction of the base metal heat input and keep the wire melting current regular through presenting (GTAW) bypass torch. Yang et al.[51] studied developing structures within GMAW multi-layer, single-bead AM by DE-GMAW, and supplies a theoretical foundation for its technique as shown in figure (6).

Figure Error! No text of specified style in document.6: Schematic Diagram of the Double Electrode GMAW-Based AM System [51].

5. GRAIN REFINEMENT ATAAMPS IN SMD PROCESSES There is a need to study and control of grain sizes through SMD methods by the common techniques for grain refining. the parts produced by SMD systems will, in general, be with large and stretched grains as appeared in figures (7) and figure (8).

Figure 7: SMD Layers and Elongated Large Grains [52], [3].

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Figure Error! No text of specified style in document.8: Etched Cross-Section (y-z Plane) of a Component Shows the Top Region and the Bottom Region with Groups Parallel to the Base Plate [20, 36].

Since the mechanical properties changes with the direction of the test, it may result in the anisotropic phenomenon [30]. Different researchers utilized external excitation systems with the end goal of grain refinements, such as weld pool stirring, arc oscillation, ultrasonic vibration, and arc pulsation [3, 52, 53]. Figure (9) shows the impact of the arc oscillation by vibrating the welding torch on the grain refinement.

Figure 9: (a) Effect of arc Vibration Amplitude on Grain size in Al-2,5 Mg, (b)Effect of Oscillation Process in Refining the Dendrites in the Fusion Zone [54].

Wang et al.[16] researched the effects of direct current pulse GTAW parameters on the morphology of the Ti6Al4V. They reasoned that there is no grain refinement in the WAAM parts of Ti6Al4V alloy deposited at both low or low and/or high-frequency pulsed current due to how the titanium solidifies by planar and cellular rather than dendritic growth. In the pulsed arc technique, the low-current cycle or background current which is sometimesless than 50% of the peak current, so that a sudden 34 reduction in heat input occurs which leads to refining the grains as shown in figure (10) [55, 56].

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Figure Error! No text of specified style in document.10: Equiaxed Grains in Pulsed arc-weld of 6061 Al-Alloy [55, 56].

While the work [57] expressed that AC was considerably more viable than DC in refining the FZ of Ti-6Al-4V welds since the pulse AC causes a more noteworthy tumult in the weld pool. Creators of the works [20, 36] utilized the interpulse GTAW system as a heat source for the fabrication of large structural Ti-6Al-4V. Also, there are several methods can be used to enhance the characteristic properties of the macrostructure and microstructure of the components produced by AM methods. Zhang et al. [58] investigate the effects of electromagnetic stirring on the microstructures of pipe-line steel SAW deposited metal. The results of the study showed that electromagnetic stirring increased the number density of inclusions with 0.2-0.6μm in diameter and promoted the formation and refining of acicular ferrite within austenite grains. The low-temperature toughness of deposited metal was improved.

Many types of research have been done on the pulsed TIG-ARC process. Ramkumar et al.[59]used Pulse and conventional TIG welding to study the weldability of AISI 904L stainless steel. They have demonstrated that the PCTW generally provides better tensile properties compared to CCTW weldments.Yilmaz et al. [29] investigated the effects of different process parameters on the macrostructure and microstructure of the deposited AISI 308LSi parts. They clarified and compared the morphology and microstructure of the parts manufactured by the traditional method and pulsed current TIG-SMD methods. It has been found pulse frequency has a significant effect on the breaking of the dendrite arms during the welding process and so strongly influences the tensile strength and microhardness as shown in figure (11).

Figure 11: In the Pulsed Current Process, the Grain Refinement Non-Pulsed (0 Hz) (a), 5 Hz (b), 500Hz (c), and 2000 Hz (d). [29].

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properties of the weldments, especially for the Type 304 ASS [60, 61].Guo[62] presented the feasibility to manufacture AZ31WAAM parts. Such an accomplishment was obtained with GTAW technology by using six different pulse frequencies (1, 5, 10, 100, and 500 Hz), with the corresponding microstructures showed in figure (12). Samples constructed with 5 and 10 Hz presented higher surface waviness, but the size of grains was smaller and finer.

The weld pool gets in resonance with these frequencies, and as a result, the rates of cooling decreased enhancing a finer structure. Sample constructed with 5 Hz presented an ultimate tensile strength of 258 MPa and an elongation of 25.6%, while sample constructed with 10 Hz presented an ultimate tensile strength of 263 MPa and an elongation of 23%. Overall, the samples produced designated good plastic behavior.

Figure Error! No text of specified style in document.12: Microstructure of Samples Formed with a Frequency of (a) 500 Hz, (b) 100 Hz, (c) 10 Hz, (d) 5 Hz, (e) 2 Hz, and (f) 1 Hz [62].

Some of the research discussed several techniques to improve the outcome quality of the products produced by the GMAW process. Pulsed MIG is probably the simplest and most cost-effective of the different welding processes that can be used for WAAM technique, Cold Metal Transfer (CMT) will allow depositing layers with low heat input, high process tolerance, plasma, and high power fiber laser are adequate for small high-quality parts while for achieving the highest productivity Tandem MIG is the most promising technique. Tandem pulsed MIG welding technique, in which two wires are fed with pulsed welding currents supplied individually [63].

Martina et al.[48] In their work have found that the use of Pulse MIG welding technique with a tandem torch was suitable for the high deposition rate as the dual wire feeding technique increased the deposition by two times with the process being stable at higher deposition rate.

Additionally, this variant is characterized by its low heat input and by the preservation of nucleation particles. Figure (13 a,b) depicts the macrostructure of aluminum with conventional cold metal transfer and with CMT-PADV, respectively, where the non-existence of pores with CMT-PADV is visible.

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Figure 13: Porosity Presence in Samples Manufactured with: (a) Conventional Cold Metal Transfer; (b) Cold Metal Transfer-Pulse Advanced.

Zhang et al.[64] studied a power source mode named variable polarity cold metal transfer (VP-CMT). The pulsed arc mode consequences in an oscillation, that in relationship with alternating arc polarity changes, that disruptions the dendrite arms, providing heterogeneous nucleation sites.

The typical columnar grains converted into equiaxed and a grain refinement effect was observed. Despite isotopic grains established by microscopy techniques, only an alteration of 8% in ultimate tensile strength from horizontal and vertical samples was possible, due to the presence of interlayer pores.

7. ULTRASONIC VIBRATIONS IN GMAW Gas metal arc welding (GMAW) uses an electric arc, produced between a consumable wire electrode and workpiece, to melt and join the workpiece [65]. The Production of high quality and defect-free GMAW welds involves controlling process parameters such as arc length, voltage, and current ratings, wire feed rate, etc. On the other hand, the GMAW process is not stable because it produces spatters and welding fumes [66-69]. The window of process parameters to attain a stable arc is narrow because the welding voltage is very small, of the order 2 V [70].To discourse these problems, ultrasonic vibrations were integrated with the GMAW process in different approaches. The main idea of applying ultrasonic vibration in GMAW was to bring about differences in metal transfer in GMAW by the ultrasonic effect and to use the ultrasonically induced grain refinement criteria which are predictable to improve weld mechanical properties. It was seen that the GMAW weld construction and grain refinement increased significantly with ultrasonic vibrations [71-73]. Furthermore, the welding arc can also be integrated with the pulse current to create the ultrasonic wave in the ultrasonic frequency range [74-76].

Therefore, the arc source performance as the heat source as well as the ultrasonic wave emitter. Using this setup, high grain refinement and enhanced mechanical properties are realized. Fan et al. [77] studied the short circuit-ing transmission mode of the ultrasonic-assisted (UGMAW) method. It was seen that when ultrasonic vibrations are applied directly to the workpiece, substantial grain refinement of weld occurs [78, 79]. Further, they integrated ultrasonic vibrations in GMAW to be able to separate the droplets. It was found that the droplets became elongated along the wire axis but their size was reduced as compared to those untraditional GMAW. It indicated that the application of the ultrasonic vibrations caused an increase in wettability [77, 80]. Xie et al.[81] investigated the effect of acoustic field parameters on arc acoustic binding during ultrasonic wave-assisted arc welding. They started a model for a cylindrical parameter where the incident acoustic field was described based on the boundary element equation. From the model, the maximum acoustic radiation power was initiate to be in the first resonant mode. When applying the ultrasonic vibrations, the shortening of welding arc creating arc acoustic www.tjprc.org

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binding [82]. Additionally, the weld penetration was improved and grains were more refined, as shown in Figure(14) [83].

The previous studies were restricted to aluminum, mild steel but new welding tools have included structural steel and titanium.

The increase of the welding current and the load gives extra advantages. It is also evident that improved weldability and process efficiency can be experienced for thick and hard metal sheets through advanced power source parameters, especially over short-circuiting, controlled polarity, and electrode wire motion.

Figure 14: Weld Penetration of (a) Conventional Arc Welding and (b) Ultrasonic Wave-Assisted Arc Welding [83].

8. VIBRATED LASER BEAM MELTING The sequent literature is about utilizing the vibration in one of the additive manufacturing techniques Laser Beam Melting (LBM) is one of the widespread Am methods that have been widely used in the last two decades. This layer-based technology produces high-quality; plastic parts beneficial for design approval, trial, and test, or useful components in true working environments [84]. One of the most promising approaches to control powder flow is the utilizing of vibration which was studied by several research groups in recent decades [85-89]. They revealed that vibration excitation can improve the powders’ flow properties by breaking down agglomerated powder particles and fluidizing it which is especially beneficial for powders with low flowability.Stichel et al. [90] experimented a setup basing is provided on the steel nozzles that vibrate longitudinally applied to the laser beam melting. the result of this experiment demonstrates that the layers achieved using the blades used with typical laser beam melting devices are still useful Compared to the layers prepared by the nozzle setup.

This shows that optimization is requisite to create high-quality Usable layers for LBM applications.

9. CONCLUSIONS SMD based on ALM is a new technology of the most popular techniques in the manufacture of products that are difficult to form and cut in the normal operating machines. SMD is a new technology that can produce net-shaped or near net-shaped products by depositing a filler metal (mostly of metallic wires) in the form of a layer on a layer. In this study, many types of research used the electric pulse arc, stirring the weld pool, vibrate the pulse arc, vibration excitation of LBM as a method to enhance the quality of the parts manufactured by welding or deposition of metals. Due to the high deposition rate, SMD is a promising technique for producing large features with high complexity, such as balanced cruciform, flanges, and stiffened panel. One of the purposes of this study is to provide an overview of the methods used to improve the final quality of the manufactured parts of the AM methods and SMD using WAAM. Furthermore, studied the materials used in the CMT and DW-SMD process, microstructure, and mechanical properties of the SMD system.SMD process using WLAM Process and SMD using WAAM. WAAM is divided into SMD using single wire-GMAW (SW-GMAW) and SMD using double wire GMAW (DW-GMAW). In addition to the SMD process, there is new technology, which is CWF plus MIG-welding.

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The main remarks and conclusions from the present work can be summarized as follows: •

WAAM process is a term or concept that produces a wide range of options for manufacturing or forming large and lightweight structures. WAAM process is particularly useful for example in manufacturing or repairing parts of the aviation industry where complex and lightweight structures are required. Due to the high flexibility of the WAAM process, these parts can be specificallydesigned.

•

SMD processes are appropriate for fabricating the aerospace parts. Also, it has been provided as anexceptional and low-cost solution for the manufacture or construction of structural components within a wide range due to the high deposition rate, high efficiency, and high density. This technique is contained by many weldable materials such as, for example, Ti-6Al-4V, stainless steel 304, 308L, 309L, 316L, and Inconel 718.

•

The SMD process represented by the MIG-3D welding technique usually fabricates very dense parts.

•

MIG welding with CMT is an innovative process for depositing material to be widely formed and based on excellent quality, high efficiency compared to other welding processes such as TIG welding and heat source efficiency are high compared to TIG welding.

•

There are some of the developed techniques such as Tandem-GMAW, Variable-Polarity GMAW (VPGMAW),and DW-GMAW were created to solve the problems of distortions and cracking due to increasing the deposition rate and hence doubling the production rates. CWF plus MIG-welding technology is one of the most modern techniques for metal deposition.

•

The mechanical properties effected by the microstructure and macrostructure of the components produced by the SMD process.

•

The properties of the parts can be enhanced by adding features to the SMD machine. ultrasonic vibration and pulsing can enhance the properties by breaking down the dendritic grains formed during the deposition process, therefore, the grains become smaller and finer which results in higher strength and tensile test values.

•

The ultrasonic vibration can be integrated with the LBM process and as a result, improve the powders’ flow properties by breaking down agglomerated powder particles and fluidizing it which is especially beneficial for powders with low flowability and create high-quality layers for LBM applications.

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