Cold spray process principles allow the production of near-net-shape metal parts with a fast layer deposition by using 3D printing techniques via supersonic 3D deposition (SP3D). This innovative additive manufacturing process allows an easy and quick production of copper and aluminium parts with future possibilities to expand materials and alloys. The speed and materials enable the application of this cold spray based 3D printing process for the production of tools. In this paper, Electrical Discharge Machining (EDM) electrodes were fabricated by using SP3D to investigate its application in tool production. Requirements for the materials of electrodes and some existing solutions for the production of EDM electrodes with additive manufacturing methods are described first. The fabrication and experimental results are then presented for 3D printed copper EDM electrodes that were tested by using St 37-2 (DIN 17100) steel as the workpiece.

Increasing student motivation and engagement in classroom (and during the study in general) is the aim of every lecturer. Never stopping development of new digital tools and media present a new challenge in the educational process. The...

Student success in Dynamics, a core subject in Mechanical Engineering courses, requires conceptual understanding of complex systems. Dynamics covers motion of particles and objects, and usually relies on 2 dimensional images and/or written descriptio...

In this paper, the influence of two selected parameters (the welding time and the presence of the activating flux on the surface of the base metal) on the weld joint at Stud Arc Welding process is investigated. In the experimental part of the paper, the drawn arc stud welding process with the ceramic ferrule is applied with the different welding time and the application of the activating flux for ATIG process. In order to evaluate the influence of the welding time and the activating flux on the weld characteristics, the cast zone width and Vickers hardness HV 0.2 are measured

The application of stud arc welding process is well known in various manufacturing fields and civil engineering due to simplicity of application, short welding time and cost efficiency. In this paper, application of on-line monitoring of main welding parameters (welding current and voltage) is used in the examination of process stability during stud arc welding with ceramic ferrule. The goal of this experimental work is to make the best choice of monitored welding parameter to assure the high quality of arc stud weld joint. So, the applicability of stability evaluation methods usually used in MAG (Metal Active Gas) welding process is analyzed for stud arc welding application. The connection between stability of stud arc welding process and weld quality is evaluated through macro section analysis of the welded joints

Duplex stainless steel (DSS) blends impressive mechanical and chemical characteristics to withstand aggressive environments. Its fabrication by Gas Metal Arc Welding-Additive Manufacturing is an emerging research topic. However, its sensitive grain structure and alloy composition are prone to deterioration by repeated thermal shocks. Whether optimal weld parameters can resolve these challenges without additional costs from special fillers, gases, or mechanisms is a valid question. In this study, how different wire feed speeds, travel speeds, and weld voltages, chosen from a set of preliminary beads, translate into wall dimensions, phase formation and distribution, morphological transformation, and elemental segregation is investigated. The unique DSS microstructures were characterised using scanning electron microscopy and energy-dispersive spectroscopy to reveal differences in microstructural evolution and ferrite-austenite (α-γ) structure. The deposited walls exhibited satisfactory geometric quality with negligible distortions. However, the height suppression was noticeable at the deposition energy (DE) of 755 J/mm. Metallographic analysis revealed low γ phase formation (70%) in the high DE wall (755 J/mm). The parameters WFS:TS = 15, TS = 35 cm/min, WFS = 525 cm/min, and V = 20.804 volts suppressed the elemental segregation while maintaining a suitable phase balance without post-processing.