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Öğe A review on aluminum alloys produced by wire arc additive manufacturing (WAAM): Applications, benefits, challenges and future trends(Elsevier, 2024) Sarikaya, Murat; Onler, Dilara Basil; Dagli, Salih; Hartomacioglu, Selim; Gunay, Mustafa; Krolczyk, Grzegorz M.Metal additive manufacturing is advancing with increasing momentum and attracting great attention. The Wire Arc Additive Manufacturing (WAAM) process, one of the metal additive manufacturing methods, involves melting a filler wire with an electric arc and depositing metal droplets layer by layer along the planned path. Aluminum alloys produced by the WAAM process have been in high demand in the industry, especially in the last decade. The WAAM process stands out as a suitable method for many industries due to its low investment cost, high deposition rates and the advantages of creating relatively complex parts. Key application areas of aluminum alloys produced using WAAM include aerospace, automotive, marine, and energy sectors, where lightweight structures, corrosion resistance, and high strength are critical. Much research has been done and innovative applications, including hybrid systems, have been developed to prevent defects such as residual stresses, cracks, porosity and delamination. This review article provides a comprehensive overview of the use of the WAAM process in aluminum alloys over the past decade. In the article, firstly, aluminum alloys, the WAAM technique and its types are introduced. In the following section, the methods used to improve mechanical properties and optimize the microstructure are examined in detail. In the next section, the difficulties encountered when using aluminum alloys in WAAM applications are discussed in detail. In the discussion section, current developments are evaluated, and in the last section, suggestions for future studies and inferences obtained from this study are presented. As a result, WAAM-CMT and hybrid systems were found to be effective in reducing defects such as porosity, distortion and residual stress. In addition, post-processing heat treatments and surface treatment methods are also crucial for improving mechanical properties. Finally, more research is needed in the areas of 7xxx series alloys, repair applications and environmental sustainability.Öğe Analysis of machinability and sustainability aspects while machining Hastelloy C4 under sustainable cutting conditions(Elsevier, 2023) Yildirim, cagri Vakkas; Sirin, Senol; Dagli, Salih; Salvi, Harsh; Khanna, NavneetIn recent years, developments in the defense, aerospace, and medical industries have significantly increased the expectations regarding material performances. In particular, the demand for materials that can withstand very high and/or very low temperatures and harsh mechanical/chemical conditions has increased. The superior qualities of superalloys can adequately meet this demand. However, the difficulties encountered in the machining of these alloys cause some burdens both ecologically and economically due to the use of cutting fluid. Therefore, the use of cost-friendly and sustainable cutting fluids in the production industry has a vital role, both in terms of machining performance and the environment. From this perspective, this paper focuses on the effects of various cutting environments, i.e., Dry, MQL, LN2, N-2, CO2, Vortex, LN2 + MQL, N-2 + MQL, CO2 + MQL, and Vortex +MQL on the machining performance of Ni-based C4 alloy. Additionally, it was aimed to reveal the effect of cooling/lubrication methods on sustainability by performing a sustainability analysis. Firstly, surface roughness, power consumption, tool wear and mechanisms, and cutting temperature were considered as performance characteristics. When examined in terms of machinability, Vortex + MQL gave the best result in terms of surface roughness and power consumption, while LN2 gave the best result in terms of cutting temperature. Then, a comprehensive sustainability analysis was carried out. As a result, the CESMO follows the order of Dry > MQL > LN2 > LN(2 +)MQL > CO2 > CO2 + MQL > N-2 > N-2 + MQL > Vortex > Vortex + MQL. While employing Vortex + MQL cutting condition, the CESMO decreased by about 11.37% as compared to Dry cutting condition. While using a combination of different sustainable lubrications or coolants, the overall carbon emissions decreased in the range of about 15-25% approximately as compared to the employment of the individual cutting conditions (i.e., coolant/lubricants).Öğe Characterization, generative design, and fabrication of a carbon fiber-reinforced industrial robot gripper via additive manufacturing(Elsevier, 2024) Hartomacioglu, Selim; Kaya, Ersin; Eker, Beril; Dagli, Salih; Sarikaya, MuratRobot grippers are crucial components across various industrial applications, requiring special design and production for obtaining the optimal performance. Conventional plastic injection moulding techniques fall short in achieving the specificity needed for these grippers. To address this challenge, current paper focuses on developing a robot gripper using carbon fiber-reinforced polyamide with a next-generation composite filament and employing the innovative Generative Design technique. In the work, we began by characterizing and optimizing the composite material specifications. Then, the tensile strength and fracture mechanics of standard samples based on printing parameters, applying Taguchi experimental design for optimization were evaluated. Analysis of Variance (ANOVA) was used for factor analysis to fine-tune the process. Using the Generative Design technique, we determined optimal geometries, which were then fabricated through Fused Deposition Modeling (FDM). As a result, the optimization efforts led to significant improvements i.e., tensile strength increased from 103.2 to 116 MPa, and the elasticity modulus from 8386 to 8990 MPa. In practical industrial applications, we achieved a reduction in material weight from 14 to 4 g, lowered production costs from $5.16 to $1.50, and cut production time from 58 to 28 min. This study presents a validated method for developing industrial products with reduced material usage and costs, promoting sustainable production practices.Öğe Investigation of bending behavior of two and three-dimensional honeycomb and auxetic sandwich beams(Sage Publications Ltd, 2024) Yazici, Mustafa Enes; Kanber, Bahattin; Dagli, SalihThe bending behavior of two (2D) and three-dimensional (3D) sandwich beams that have a negative Poisson's ratio (auxetic) and conventional honeycomb was investigated for different geometries, sheet thicknesses, and cell thicknesses. The re-entrant and solid specimens were produced with a stereolithographic (SLA) 3D printer and subjected to a three-point bending test under the conditions specified in the ASTM C393 standard. The data obtained from the tests were used to verify finite element analysis (FEA) results. The radius of curvatures was calculated for each specimen depending on the load step. In addition, Poisson's ratio was calculated for each auxetic sample. As a result, the 3D arrowhead beam, with a cell thickness of 1 mm and a sheet thickness of 2 mm, exhibits peak force values that are 497.340% and 461.500% higher than re-entrant and missing rib beams, respectively. Besides, the maximum strain energy values of same 3D arrowhead specimens (596.120 mJ) are higher than re-entrant (101.032 mJ) and missing rib (108.201 mJ) specimens. It was determined that the arrowhead is the most durable structure compared to other auxetic structure geometries. Therefore, when arrowhead and honeycomb 3D beams are compared, it was observed that the maximum strain energy of arrowhead specimens was higher in both horizontal (84.310%) and perpendicular (131.910%) positioned specimens. Comparing the arrowhead and honeycomb 2D beams with the highest maximum strain energy, it can be concluded that the arrowhead beam absorbs 20.000% more energy.
