The influence of welding angle, welding current, travel speed, pulse time, and torch height on the geometry, macrostructure, and mechanical properties of Tungsten Inert Gas (TIG) orbital welding on an SUS 304 stainless steel pipe is investigated in this study. The results show that an electrode angle of 45° produces better weld joints than angles of 30°, 60°, 90°, and 120°. Furthermore, the electrode angle of 30° results in an acceptable weld width but a low depth of penetration (DOP) value. Welding current and weld speed have a significant impact on heat dispersion during TIG welding of an SUS 304 stainless steel pipe. The high welding current may result in blow-hole flaws, particularly near the conclusion of the welding process when heat is accumulated. A long torch height of 2 mm causes unevenness in the weld joints because the arc may be distorted when compared to shorter torch height cases. The pulse time of 0.2 s is too lengthy for a low-welding current situation because it will generate a small weld pool. As a result, the weld pool solidification process speeds up, and porosity emerges in the weld bead. A pulse time of 0.1 s results in a better weld joint. To avoid blow-hole creation, the welding current should be gradually reduced during the process. In addition, the Taguchi results demonstrate that the welding current has the greatest effect on the ultimate tensile strength (UTS) value, followed by welding speed, pulse time, electrode angle, and torch height. Furthermore, the ideal parameters for the UTS value are an electrode angle of 45°, a torch height of 2.0 mm, a welding current of 174 A, a welding speed of 72 mm/min, and a pulse time of 0.3 s.

This study aims to explore the effects of Thermoplastic Polyurethane (TPU) content on the weld line properties of Polypropylene (PP) and Acrylonitrile Butadiene Styrene (ABS) blends. In PP/TPU blends, increasing the TPU content results in a significant decrease in the PP/TPU composite’s ultimate tensile strength (UTS) and elongation values. Blends with 10 wt%, 15 wt%, and 20 wt% TPU and pure PP outperform blends with 10 wt%, 15 wt%, and 20 wt% TPU and recycled PP in terms of UTS value. The blend with 10 wt% TPU and pure PP achieves the highest UTS value of 21.85 MPa. However, the blend’s elongation decreases due to the poor bonding in the weld line area. According to Taguchi’s analysis, the TPU factor has a more significant overall influence on the mechanical properties of PP/TPU blends than the recycled PP factor. Scanning electron microscope (SEM) results show that the TPU area has a dimple shape on the fracture surface due to its significantly higher elongation value. The 15 wt% TPU sample achieves the highest UTS value of 35.7 MPa in ABS/TPU blends, which is considerably higher than other cases, indicating good compatibility between ABS and TPU. The sample containing 20 wt% TPU has the lowest UTS value of 21.2 MPa. Furthermore, the elongation-changing pattern corresponds to the UTS value. Interestingly, SEM results present that the fracture surface of this blend is flatter than the PP/TPU blend due to a higher compatibility rate. The 30 wt% TPU sample has a higher rate of dimple area than the 10 wt% TPU sample. Moreover, ABS/TPU blends gain a higher UTS value than PP/TPU blends. Increasing the TPU ratio mainly reduces the elastic modulus of both ABS/TPU blends and PP/TPU blends. This study reveals the advantages and disadvantages of mixing TPU with PP or ABS to ensure that it meets the requirements of the intended applications.

In this study, Nylon 6 (PA6) was reinforced with glass fibers and molded using different injection parameters. The PA6 samples were then subjected to fatigue tests, and the results were processed to study (i) how the glass fibers affected the PA6 fatigue displacement and (ii) which injection parameters influenced the PA6 fatigue property. To do so, single-factor experimental designs were implemented in which the control factors were the glass-fiber percentage, the melt temperature, the hold pressure, the hold time, the injection pressure, and the injection time. Correlational analyses were used to predict the relationships between the control factors and fatigue results. A two-factor design was then applied to determine the two factors that influenced the PA6 fatigue displacement the most, with analysis of variance being used to determine how the factors affected the fatigue property. In this study of injection plastic, the glass-fiber percentage of PA6 composite was found to be the main factor that affected the fatigue displacement the most.

Three-dimensional (3D) printing is a method of additive manufacturing that involves creating objects by serial deposition for pre-production or production. After designing a 3D model with a CAD program, a processable file is customized to create a layered design, which is then printed. Although this technique costs more than traditional techniques, such as metal injection molding, metal 3D printing can significantly improve the production times of lightweight parts produced in small numbers. Furthermore, is improves flexibility, and is more able to produce complicated geometries that would not be possible with common methods, such as turning, milling or drilling. The fused deposition modeling technique uses a metal powder filament, which is pulled through a high-temperature extrusion nozzle, thus melting the material; after that, the printed parts are placed in the debinding station with a solvent to remove the wax from the powder. Finally, completed products are taken from the sinter furnace with inert gases. Depending on the material, different characteristics arise in the production process, and the produced parts manifest different mechanical properties. This paper describes some experiments performed on the fused deposition modeling method using stainless steel filaments, debinding Opeteon and a sinter furnace.

This study investigates the effects of arc length, current intensity, travel speed, gas flow rate, and pulse time on surface hardness to better understand the arc quenching of S45C steel with a curved shape. With the standard examination method, increasing the current intensity, Travel speed, and arc length causes the surface hardness to decrease. The surface hardness varies depending on the gas flow rate and pulse time. The Travel speed factor appears to have the greatest effect, followed by the gas flow rate and current intensity. Pulse time and arc length are ranked fourth and fifth, respectively, indicating a smaller impact on surface hardness. The microhardness diagram is divided into four stages: improving, rapid dropping, moderate dropping, and stable. The greatest hardness was 576 HV, with a case depth of 1200 μm. The structure of the arc-hardened sample is composed of hardening zones, HAZ, and base metal. The base metal is composed of ferrite and pearlite, which are the original microstructures of medium-carbon steel. The HAZ is made up of two phases: a brown bainite phase and a brighter ferrite phase. Ferrite, bainite, martensite, and residual austenite phases make up the hardening with a high hardness value area. These phases’ diversity results from their rapid heating and cooling rates as well as the significant variations in cooling rates among depths. The findings of the study on the optimum values of factors such as current intensity at 150 A, Travel speed at 150 mm/min, arc length at 2.5 mm, pulse time at 0.6 s, or gas flow at 10.5 l/min can help engineers to have a closer look at the parameters of this arc tempering technology affecting the surface hardness and their applications. Moreover, the hardness measurement value according to the Taguchi method investigation also shows that the highest value of surface hardness achieved is 42.6 HRC compared to 18 HRC of unhardened surface hardness. In addition, the findings on microstructure also help the applicator to better understand and evaluate the quality of this electric arc method for quenching the surface of S45C steel, thereby making it more useful in the industry.

This study investigates the fatigue bending strength, measured as the Mean of Fatigue Cycles (N), of cylindrical components produced by external wire arc additive manufacturing (WAAM) through a Taguchi L25 orthogonal array and linear regression analysis. Five welding parameters—welding current (Ampe), offset distance (mm), step length (mm), welding speed (mm/min), and specimen gauge diameter (mm)—were evaluated to maximize N using signal-to-noise (S/N) ratios. Nominal bending stresses (σ) ranged from 45 to 54 MPa, ANOVA on raw replicate data (25 runs, 3 replicates) confirmed specimen gauge diameter = 17 mm and weld current = 125 A as dominant, with F = 171.62 (p < 0.001, eta² = 0.62 [95% confidence intervals (CI) 0.55–0.68]) for specimen gauge diameter and F = 6.13 (p < 0.001, eta² = 0.13 [95% CI 0.08–0.18]) for weld current, accounting for ~75% of the variance. Optimal settings (offset distance = 3.0 mm, step length = 1000 mm, welding speed = 550 mm/min, specimen gauge diameter = 17 mm) achieved S/N = 111.35 dB, predicting N ≈ 350,000–380,000 cycles, a 22–33% improvement. Interactions between specimen gauge diameter and speed, and between weld current and offset distance, suggested enhanced strength at speed = 400–450 mm/min for specimen gauge diameter = 17 mm. Basquin’s law (b ≈ 0.72, R² = 0.992) confirmed weld current as key. The linear regression model (adjusted R² = 0.9506) had coefficients for specimen gauge diameter (+70,120 cycles/mm, p < 0.001) and weld current (+1088 cycles/Ampe, p = 0.02), but lower test R² = 0.7212 via cross-validation (60/20/20 split) indicates overfitting due to small dataset size (25 runs), suggesting larger datasets or nonlinear models (e.g., polynomial regression, RSM). Confirmation runs (N = 317,082, 95% CI [287,000–347,000]) validated the results within ~13% error. WAAM reaches 80–90% of traditional manufacturing (TM) fatigue performance, with a 10–20% gap due to the microstructure; recommendations include post-treatments and safety factors (~1.2).