Investigate strategies for moving heat sources in the process of heating metal on a flat surface

MINISTRY OF EDUCATION AND TRAINING
HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION
FACULTY FOR HIGH QUALITY TRAINING

CAPSTONE PROJECT
ELECTRONICS AND TELECOMMUNICATIONS
ENGINEERING TECHNOLOGY

INVESTIGATE STRATEGIES FOR MOVING HEAT
SOURCES IN THE PROCESS OF HEATING METAL ON A
FLAT SURFACE

LECTURER: PGS. TS PHẠM SƠN MINH
STUDENT: NGÔ ĐỨC TÀI
LÊ MINH NHI
HOÀNG MẠNH THẮNG

S K L 01 0 8 8 9

Ho Chi Minh City, 2023


MINISTRY OF EDUCATION AND TRAINING
UNIVERSITY OF TECHNICAL AND EDUCATION
HO CHI MINH CITY
FACULTY OF HIGH QUALITY TRAINING
⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯

MECHANICAL ENGINEERING TECHNOLOGY

GRADUATION THESIS

INVESTIGATE STRATEGIES FOR MOVING HEAT
SOURCES IN THE PROCESS OF HEATING METAL ON A
FLAT SURFACE
Instructor: PGS. TS PHẠM SƠN MINH
Student:

NGÔ ĐỨC TÀI

ID: 19144074

LÊ MINH NHI

ID: 19144061

HOÀNG MẠNH THẮNG

ID: 19144070

Course year: 2019 - 2023

Ho Chi Minh city, July 2023


UNIVERSITY OF TECHNICAL AND EDUCATION
HO CHI MINH CITY
FACULTY OF HIGH QUALITY TRAINING
MECHANICAL ENGINEERING TECHNOLOGY
⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯

COURSES: GRADUATION THESIS

`

GRADUATION THESIS
INVESTIGATE STRATEGIES FOR MOVING HEAT
SOURCES IN THE PROCESS OF HEATING METAL ON A
FLAT SURFACE
Instructor: PGS. TS PHẠM SƠN MINH
Student:

NGÔ ĐỨC TÀI

ID: 19144074

LÊ MINH NHI

ID: 19144061

HOÀNG MẠNH THẮNG

ID: 19144070

Course year: 2019 - 2023

Ho Chi Minh city, July 2023


HCM UNIVERSITY OF TECHNOLOGY AND
EDUCATION

SOCICALIST REPUBLIC OF VIETNAM

Independent - Freedom – Happiness

FACULTY OF HIGH QUALITY TRAINING
Courses: graduation thesis

GRADUATION THESIS MISSIONS
Semester 2 / academic year: 2022 – 2023
Instructor: PGS. TS PHẠM SƠN MINH
Students:
1. NGÔ ĐỨC TÀI

19144074

Contact: 0388060002

2. LÊ MINH NHI

19144061

Contact: 0981478011

3. HOÀNG MẠNH THẮNG 19144070

Contact: 0767046782

1. Number of topic: 22223DT69
Name of topic: Investigate strategies for moving heat sources in the process of heating metal
on a flat surface

2. Initial Data and Documents:
- Luận văn thạc sĩ: NGHIÊN CỨU ẢNH HƯỞNG THÔNG SỐ HÀN ĐẮP ĐẾN ĐỘ BÊN
KÉO CỦA LỚP ĐẮP – Nguyễn Cơng Chính.
- Welding and Repair Options.
- Using CNC Machines and TIG Welding.
3. Main Content of the Project:
- Overview of Welding and Repair Technology
- Understanding the parameters of welding by layer
- Performing welding on various samples corresponding to different options
4. Expected Deliverables
- Realistic product model
- Analytical report
5. Date assigned to the project: March 15, 2023
6. The deadline for project submission: July 15, 2023
English 

Vietnamese 

Protection presentation: English 

Vietnamese 

7. Presentation language: The report:

i


HEAD OF DEPARTMENT
(Sign, write full name)

SENIOR MANAGER
(Sign, write full name)

 Allowed to defend the graduation thesis................................................
(Instructor sign, full name)

ii

INSTRUCTOR
(Sign, write full name)


COMMITMENT
-

Name of topic: Investigate strategies for moving heat sources in the process of heating
metal on a flat surface.

-

Students:

-

Ngô Đức Tài

19144074 Contact: 0388060002

Lê Minh Nhi

19144061 Contact: 0981478011

Hoàng Mạnh Thắng

19144070 Contact: 0767046782

Graduation thesis submission date:
Commitment: "I hereby declare that this graduation thesis is the result of my own research
and work. I have not copied from any published articles without proper citation. If any
violation occurs, I take full responsibility."
Ho Chi Minh City, 27 July, 2023
Signature

iii


SPECIAL THANKS
We would like to express our sincere and profound gratitude to the teachers at the
University of Technical Education in Ho Chi Minh City for their guidance, teaching, and
invaluable support throughout the implementation of our graduation project titled
“Investigating Heat Source Movement Strategies in the Process of Heating Metal on a Flat
Surface”. We deeply appreciate the dedication and assistance provided by our esteemed
instructors during this period.
First and foremost, we would like to express our gratitude to the teachers for
imparting the knowledge and skills necessary for us to successfully complete this project.
The knowledge we have gained not only helped us grasp the theoretical foundations but also
supported us in conducting experiments and analyzing dat.
We would also like to express our gratitude to Ph.D Pham Son Minh, Ph.D Tran
Minh The Uyen, Ph.D Nguyen Van Thuc, Mr. Truong Thanh Cong, and Mr. Nguyen Van
Mang for providing us with the necessary materials and equipment to conduct the

experiments. Thanks to their support, we were able to carry out the experiments accurately
and reliably.
Furthermore, we deeply appreciate the advice, guidance, and support provided by the
teachers throughout the project. The valuable input and contributions from the instructors
have helped us improve our project to the best of our abilities.
Once again, we would like to express our gratitude for the excellent facilities
provided by the university, including state-of-the-art laboratories, diverse research materials,
and a friendly learning and working environment. All of these have created a conducive
atmosphere for us to conduct our experiments and research effectively.

iv


ABSTRACT
Investigate strategies for moving heat sources in the process of heating metal on a flat
surface( Khảo sát các phương án di chuyển nguồn nhiệt trong q trình nung nóng
kim loại đắp trên nền phẳng).
The research project focuses on studying the process of heating metal on a flat
surface and investigating various heat source movement strategies during this process. The
objective of the research is to understand and evaluate the effectiveness of different heat
sources movement options to enhance the heating process of metal on a flat surface.
To achieve this objective, the research utilizes an experimental approach to conduct
experiments with different heat source movement strategies. These strategies may involve
horizontal, vertical, rotational, or combined movements of the heat source during the
process of heating the metal.
During the experimental process, parameters such as temperature, pressure, flow rate,
and uniformity are measured and recorded to analyze and evaluate the effectiveness of each
heat source's movement strategy.
In conclusion, the graduation project aims to research and evaluate different heat
source movement strategies in the process of heating metal on a flat surface, with the goal of

improving the efficiency and quality of metal production processes.

v


TABLE OF CONTENTS
GRADUATION THESIS MISSIONS ...................................................................................... i
COMMITMENT ..................................................................................................................... iii
SPECIAL THANKS ............................................................................................................... iv
ABSTRACT ............................................................................................................................. v
TABLE OF CONTENTS ........................................................................................................ vi
LIST OF TABLES ................................................................................................................... x
LIST OF FIGURES ................................................................................................................ xi
LIST OF ABBREVIATIONS ............................................................................................... xiii
CHAPER 1: INTRODUCTION .............................................................................................. 1
1.1. Put the problem ............................................................................................................. 1
1.2. Research situation in Viet Nam. ................................................................................... 1
1.3. Research situation of orther contries............................................................................. 2
1.4. Graduation project goals ............................................................................................... 2
1.5. Objects, research scope of the topic .............................................................................. 3
1.5.1. Research subjects ................................................................................................... 3
1.5.2. Research scope of the topic.................................................................................... 3
1.6. Research method ........................................................................................................... 3
1.6.1. Theoretical research ............................................................................................... 3
1.6.2. Experimental study ................................................................................................ 3
1.7. The scientific and practical significance of the graduation project topic ..................... 3
1.7.1. Scientific significance ............................................................................................ 3
1.7.2. Practical significance ............................................................................................. 4
1.8. Limitations of the research............................................................................................ 4
1.9. Structure of the thesis .................................................................................................... 5

CHAPTER 2: OVERVIEW OF RESEARCH TOPIC ............................................................ 6
2.1. Overview of additive manufacturing technology ......................................................... 6
vi


2.2. Classification of AM technology .................................................................................. 7
2.3. Some materials used in AM technology ...................................................................... 8
2.4. TIG electrodes welding in a protective gas environment ............................................. 9
2.4.1. General concept of TIG welding in a protective gas environment ........................ 9
2.4.2. Features of TIG welding ...................................................................................... 10
2.4.3. Advantages and disadvantages of Tig welding.................................................... 11
2.5. Welding materials and equipment .............................................................................. 12
2.5.1. Welding materials ................................................................................................ 12
2.5.2. Tungsten electrode ............................................................................................... 14
2.6. TIG weld formation and organization......................................................................... 22
2.7. General rules in the manufacture of tensile specimens: ............................................. 23
CHAPTER 3: THEORETICAL BASIS ................................................................................ 25
3.1. Tensile strength test method ....................................................................................... 25
3.1.1. Theoretical basis of tensile testing ....................................................................... 25
3.1.2. Test conditions ..................................................................................................... 26
3.1.3. Definitions of elongation ..................................................................................... 27
3.2. Methods of checking microorganism.......................................................................... 29
3.2.1. Theoretical basis .................................................................................................. 29
3.2.2. Quantitative metallographic method .................................................................... 29
3.2.3. Conduct experiments ........................................................................................... 30
3.3. Method of Scanning Electron Microscopy (SEM) ..................................................... 31
3.3.1. Theoretical basis .................................................................................................. 31
3.3.2. Operating Principles of SEM ............................................................................... 32
3.3.3. Structure of the Scanning Electron Microscope (SEM) ...................................... 32
CHAPTER 4: RESEARCH, DESIGN, AND FABRICATION OF TENSILE TEST

SAMPLES .............................................................................................................................. 33
4.1. Testing weld profiles for optimal welding parameters ............................................... 33
4.1.1. Purpose ................................................................................................................. 33
vii


4.1.2. Results of testing for welding movement option. ................................................ 33
4.2. Tentile test sample design ........................................................................................... 34
4.2.1. Sample dimensions .............................................................................................. 34
4.2.2. The case of taking a test sample .......................................................................... 36
4.3. Process tensile test sample .......................................................................................... 37
4.3.1. Prepare tools and equipment ................................................................................ 37
4.3.2 Machining of tensile test samples ......................................................................... 37
CHAPTER 5: SAMPLE INSPECTION AND EVALUATION ........................................... 41
5.1. Tensile Testing Process ............................................................................................... 41
5.1.1. Preparing tools/equipment ................................................................................... 41
5.1.2. Experiment preparation:....................................................................................... 42
5.1.3. Results obtained: .................................................................................................. 43
5.2. Microscopic observation process ................................................................................ 44
5.2.1. Equipment Preparation......................................................................................... 44
5.2.2. Sorting and cutting samples ................................................................................. 45
5.2.3. Sample preparation and observation method: ...................................................... 45
5.3 Scanning Electron Microscope (SEM) ........................................................................ 48
5.3.1. Introduction to scanning electron microscopy (SEM) ......................................... 48
5.3.2 Rate and comment results: .................................................................................... 49
CHAPTER 6: STATISTICS AND ASSESSMENT OF SUPPLY SAMPLE TEST
RESULTS .............................................................................................................................. 51
6.1. Sample parameters of the testing sample: ................................................................... 51
6.1.1. The parameters of the test samples for each option ............................................. 52
6.1.2 Evaluation of experimental results........................................................................ 54

6.2. Tensile strength parameters at the positions of the options: ....................................... 55
6.2.1. Option 1: Move the heat source in a long straight line (D). ................................ 56
6.2.2. Option 2: Move the heat source in a short straight line (N) ................................ 57
6.2.3. Option 3: Move the heat source in a short cross profiles (HC) ........................... 58
viii


6.2.4. Option 4: Move the heat source in a short curved profiles (DT) ......................... 59
CONCLUSION - RECOMMENDATIONS .......................................................................... 61
REFERENCES....................................................................................................................... 64
ADDENDUM ........................................................................................................................... I

ix


LIST OF TABLES
Table 2.1 Applications of Some Types of Gases in TIG Welding. ....................................... 12
Table 2.2 The types of gases used in TIG welding according to DIN standards. ................. 14
Table 2.3 Classification and composition of tungsten electrodes according to AWS A5.12
standard. .............................................................................................................................. 15
Table 2.4 Table for detailed dimensions during tungsten electrode grinding. ...................... 17
Table 2.5 Basic TIG welding parameters on carbon steel .................................................... 21
Table 2.6 Tensile sample size according to ASTM [7] ......................................................... 23
Table 3.1 The relationship between grain grade and grain area ........................................... 31
Table 4.1 Dimensions of tensile specimens according to ASTM [7] ................................... 35
Table 4.2 Sample cases ......................................................................................................... 36
Table 4.3 Welding parameters .............................................................................................. 37
Table 4.4 Electrode parameters ............................................................................................. 38
Table 6.1 Average test results of each option ....................................................................... 52

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LIST OF FIGURES
Figure 2. 1 Operating principle of Additive Manufacturing (AM) technology. ..................... 6
Figure 2. 2 Methods in Additive Manufacturing (AM) technology ....................................... 7
Figure 2.3 Diagram of TIG welding system ......................................................................... 10
Figure 2. 4 The various forms of tungsten electrode grinding. ............................................. 16
Figure 2. 5 Methods of grinding tungsten electrodes ........................................................... 16
Figure 2. 6 Installation diagram of TIG welding system ...................................................... 19
Figure 2.7 TIG welding guns ................................................................................................ 19
Figure 2. 9 Tig Jasic cold welding machine 250S W228 ..................................................... 20
Figure 2. 10 Argon regulator and Argon gas tank ................................................................ 22
Figure 2. 11 Tensile test specimen size................................................................................. 23
Figure 3.1Stress-Strain Curve ............................................................................................... 27
Figure 3.2 Micrometer .......................................................................................................... 30
Figure 4.1 llustrative image of welding seam movement in the case of samples and
experimental images in the top-down direction: ................................................................ 33
Figure 4.2 Illustrative image of welding seam movement in the case of samples and
experimental images in the top-down direction: ................................................................ 34
Figure 4.3 Tensile test specimen ........................................................................................... 35
Figure 4.4 Initial weld pattern parameters ............................................................................ 36
Figure 4.5 Tools and equipment for specimen fabrication ................................................... 37
Figure 4.6 Welding materials ................................................................................................ 38
Figure 4.7 Manufacturing process of tensile test piece ......................................................... 39
Figure 4.8 Welding sample fabrication process .................................................................... 39
Figure 4.9 The process of creating a Tensile sample ............................................................ 40
Figure 5.1 Tools and Equipment for Tensile Testing ........................................................... 41
Figure 5.2 Tensile Testing in Progress.................................................................................. 42
Figure 5.4 Sample before and after tensile testing ................................................................ 42

Figure 5.5 Positions identifying the tensile fracture force (Fm), upper yield point (Upper
yield point), and elastic tensile forces P1, P2 (E_Begin and E_End) on the strain graph of
the sample ........................................................................................................................... 43
Figure 5.6 Graph showing the relationship between tensile force and strain during tensile
testing .................................................................................................................................. 43
Figure 5.7 Equipment for Microscopic Observation: ........................................................... 44
Figure 5.8 The saw machine is used for cutting samples ..................................................... 45
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Figure 5.9 MP-2B Grinder Polisher machine for sample grinding and polishing. ............... 45
Figure 5. 10 Microscopic observation................................................................................... 46
Figure 5.11 Microscopic observation image taken on the microscope. ................................ 47
Figure 5.12 Microscopic observation image taken on the microscope ................................. 48
Figure 5.13 General view of scanning electron microscopy (SEM) ..................................... 48
Figure 5.14 The image captured by the scanning electron microscope (SEM) represents
option of D and N ............................................................................................................... 49
Figure 5.15 The image captured by the scanning electron microscope (SEM) represents
option of HC and DT. ......................................................................................................... 49
Figure 6.1 Shows the location of the tensile sample taken from the specimen block .......... 51
Figure 6.2 The position for microscopic observation. .......................................................... 51
Figure 6.3 Stress diagrams of different options .................................................................... 53
Figure 6.4 Histogram showing the particle-level frequencies of the different alternatives .. 53
Figure 6.5 Tensile strength comparison chart of samples and 2mm steel plate ................... 54
Figure 6.6 Comparison chart of the elongation of the samples and the original 2mm steel
plate after breaking ............................................................................................................. 54
Figure 6.7 Comparison chart of tensile strength and elongation of D profiles ..................... 56
Figure 6.8 Histogram showing the particle-level frequencies of the different alternatives .. 56
Figure 6.9 Comparison chart of tensile strength and elongation of N profiles ..................... 57
Figure 6.10 Histogram showing the particle-level frequencies of the different alternatives 57

Figure 6.11 Comparison chart of tensile strength and elongation of HC profiles ................ 58
Figure 6.12 Histogram showing the particle-level frequencies of the different alternatives 58
Figure 6.13 Comparison chart of tensile strength and elongation of DT profiles ................ 59
Figure 6.14 Histogram showing the particle-level frequencies of the different alternatives 59

xii


LIST OF ABBREVIATIONS
AM

Additive Manufacturing

SLA

Stereolithography

PBF

Powder bed fusion

WAAM

Wire Arc Additive Manufacturing

GTAW

Gas Tungsten Arc Welding

CNC

Computer Numerical Control

TIG

Tungsten Inert Gas

DCEN

Direct Current Electrode Negative

DT

Destructive Testing

NDT

Non-Destructive Testing

UTM

Universal Testing Machine

SEM

Scanning electron microscopy

SPCC

Steel Plate Cold Rolled Carbon

DMLS

Direct metal laser sintering

EBM

Electron Beam Melting

MIG

Metal Inert Gas

MAG

Metal Active Gas

LMD

Laser Metal Deposition

BMD

Bound Metal Deposition

FRMMCs

Fiber Reinforced Metal Matrix Composites

xiii

CHAPER 1: INTRODUCTION
1.1. Put the problem
Currently, metal 3D printing technology has been around for quite some time and is
widely used in many places around the world. However, in Vietnam, this technology has not
been widely adopted or known. Metal 3D printing technology can be understood as a type of
additive manufacturing (AM) method, which involves connecting materials to form the
desired object by building it layer by layer. This is in contrast to subtractive manufacturing
(SM), which is another technology that removes material to create the desired object.
According to the International ASTM Technical Committee on AM, there are seven
commonly used AM technologies: stereolithography (SLA), material jetting, material
extrusion, binder jetting, powder bed fusion (PBF), sheet lamination, and direct energy
deposition. However, most of these listed technologies commonly use metal powders and
various types of melted plastic filaments as the material forms. The use of these material forms
often leads to material shortage issues and may not meet the required hardness of the final
product. Therefore, the use of metal 3D printing technology, which combines the use of laser
energy with the melting of metal sheets, has been researched with the hope of practical
applications in large-sized components in fields such as engineering, architecture, and
maritime industries.
Similarly, WAAM (Wire Arc Additive Manufacturing) technology, which utilizes arc
welding energy to melt metal wire and additively deposit material layer by layer with
shielding gas, is another metal 3D printing technology. In the case of metal sheet 3D printing,
the material is melted in the form of sheets. It involves the combination of a robotic arm or
CNC machine with welding technology (GTAW) to create the desired shapes. The main cost
of materials primarily consists of metal sheets, which can be more cost-effective compared to
powder forms used in other layer-by-layer additive manufacturing technologies and readily
available in the market.
However, similar to WAAM technology, the strength of the additive layers is an
important consideration. By combining it with CNC machining, appropriate geometries can

be established to optimize the structural integrity of the product. Therefore, the research
project "Investigation of Heat Source Movement Options in the Metal Sheet 3D Printing
Process" aims to explore the influence of heat source movement options on the mechanical
strength and microstructural organization of the products using the WAAM method.
Therefore, the focus of this project is to research and evaluate different heat source
movement strategies in the process of heating metal on a flat surface, aiming to improve the
efficiency and quality of metal production processes.
1.2. Research situation in Viet Nam.
In recent years, the research and application of metal 3D printing technology, including
AM, have started to gain attention in Vietnam. However, studies specifically focusing on
metal sheet 3D printing are still limited, and there is a lack of research on the microstructural
organization and mechanical strength of products produced using AM technology.

1


As this field is still emerging in Vietnam, there is a need for further research and
exploration to fully understand the potential and limitations of metal sheet 3D printing. It
presents an opportunity for researchers and industry professionals to contribute to the
development and advancement of this technology within the country.
1.3. Research situation of orther contries.
Additive Manufacturing (AM) technology has been researched and developed for over 20
years. Through in-depth research, AM has increasingly advanced and found widespread
applications in aerospace, space, automotive, medical, energy, and other industries.
In the aerospace and space industries, AM is used to produce aircraft components,
rocket engines, space structures, and complex parts. AM enables the creation of lightweight
structures, improves efficiency, and reduces material waste compared to traditional methods.
In the automotive field, AM has been utilized to manufacture custom parts such as
casting patterns, exhaust pipes, brake calipers, and interior components. This technology
accelerates the production process, reduces weight, and enhances vehicle performance.

In the medical field, AM has made significant contributions by creating replacement parts,
custom implants, complex anatomical structures such as artificial hearts, dental prosthetics,
bone scaffolds, and body simulation systems.
AM is also applied in the energy sector to produce critical components for renewable
energy systems like solar panels and cast structures for power generators. With continuous
development and diversification of applications, AM has become an important tool in the
manufacturing process, offering numerous advantages over traditional methods.
In conclusion, Additive Manufacturing (AM) technology is still being researched and
developed in many places worldwide, exploring microstructure, mechanical properties, and
structural aspects such as hardness and tensile strength. However, in Vietnam, there is still
limited research related to AM. Therefore, the topic "Investigation of heat source movement
options in the process of metal deposition on a flat surface" will contribute to laying the
foundation for the development of AM technology in Vietnam.
1.4. Graduation project goals
The research project "Investigation of heat source movement options in the process of
metal deposition on a flat surface" is conducted with the following objectives:
- To survey and optimize the heat source movement options in four configurations:
vertical, horizontal, curved, and diagonal directions.
- To examine the tensile strength, hardness, and microstructural properties of the
samples after heat source movement...
- To study the relationship between welding parameters such as step over distance
between welding paths, deposition thickness, and final height of the deposited material
to achieve the desired dimensions as specified in the sample.
AM is also applied in the energy sector to produce critical components for renewable
energy systems like solar panels and cast structures for power generators. With continuous
development and diversification of applications, AM has become an important tool in the
manufacturing process, offering numerous advantages over traditional methods.
2

1.5. Objects, research scope of the topic
1.5.1. Research subjects
Research on welding options of AM technology to assess the influence on
microorganism and tensile strength of the product.
1.5.2. Research scope of the topic
The research focuses on investigating and studying the layer deposition process using
the Tungsten Inert Gas (TIG) welding method, utilizing stainless steel plate material with a
thickness of 2mm. The objective of the study is to examine the variations in heat source
movement options in four configurations and their impact on tensile strength and
microstructural properties. The evaluation and analysis of the mechanical properties of the
weld bead will be based on existing research and literature on microstructure and tensile
strength.
By conducting the research, valuable insights will be gained regarding the influence of
different heat source movement options on the mechanical properties and microstructure of
the welded samples. The findings will contribute to a better understanding of the TIG welding
process for layer deposition and provide useful information for optimizing the welding
parameters to enhance the strength and structural integrity of the fabricated products.
1.6. Research method
Combination of theoretical and experimental research.
1.6.1. Theoretical research
Refer to documents related to additive manufacturing (AM) technology.
Using the software to evaluate the experimental results, write a program to simulate the
profile for the moving plan to compare the optimality between the profiles.
1.6.2. Experimental study
Offers many moving options of different profiles, then selects the 4 most optimal
running profiles for the heat source, then uses a microscope to check the microscopic
organization and uses a tensile testing machine. to test the durability of the product. Using
statistical methods to find out the change or binding of factors affecting the product, compare
with theoretical research to be able to come up with the most optimal solution.
1.7. The scientific and practical significance of the graduation project topic

1.7.1. Scientific significance
Research Topic: Investigation of Heat Source Movement Options in Metal Heating
Process on a Flat Surface, Generating New Knowledge about the Process.
The aim of this research is to explore various options for heat source movement during
the process of metal heating on a flat surface. The study intends to provide detailed
3


information regarding the effectiveness and impact of different heat source movement
strategies, thereby opening up opportunities for further research and development in this field.
The primary objective of this research is to investigate and analyze the effects of heat
source movement on the heating process of metals. By exploring different methods of heat
source manipulation, the study aims to identify the most efficient and optimal techniques for
achieving desired heating outcomes. The research will involve conducting experiments and
collecting data on factors such as heat distribution, temperature profiles, and energy
consumption associated with different heat source movement options.
The results of this research will contribute to the generation of new knowledge
regarding the heating process of metals on a flat surface. By providing detailed insights into
the effectiveness and impact of various heat source movement strategies, the study will offer
valuable information for improving current metal heating techniques and developing novel
approaches. This research will also pave the way for further investigations and advancements
in the field.
In conclusion, this research project focuses on studying different options for moving
the heat source during the process of heating metals on a flat surface. The findings of this
study will provide in-depth information about the efficiency and effects of various heat source
movement strategies, opening up opportunities for future research and development in this
domain.
1.7.2. Practical significance
Time and Cost Savings in Production: AM technology allows for the rapid and efficient
production of complex and customized products. Instead of traditional methods that require

complex machining and assembly processes, AM enables the direct creation of products from
digital design data, reducing production time and costs.
Creating Complex Designed Products: AM enables the production of products with
intricate shapes and complex structures that are not achievable with traditional methods. This
opens up opportunities for research and development of advanced products in fields such as
healthcare, industry, and materials science...
Repair and Component Replacement: AM technology offers the ability to quickly and
conveniently repair and replace components. This is particularly useful for the maintenance
and upkeep of systems and equipment, reducing waiting time and costs associated with
component replacement.
In summary, AM technology offers significant time and cost savings in production
compared to traditional manufacturing methods. Its ability to directly produce complex and
customized products from digital design data eliminates the need for complex machining and
assembly processes, reduces tooling costs, enables on-demand manufacturing, and optimizes
material usage. These advantages make AM a valuable solution for efficient and cost-effective
production.
1.8. Limitations of the research.
The topic focuses on studying the methods of moving heat sources during the heating of
metal on flat surfaces. Check the microstructure and tensile strength of the weld specimen.
The limitation does not include the study of options for moving the heat source in other
surfaces such as curved surfaces, irregular surfaces, or specially shaped surfaces.
4


1.9. Structure of the thesis
The expected structure of the thesis, apart from the introduction and the prescribed table
of contents, will be presented in 6 chapters as follows:
Chapter 1: Introduction.
This chapter will outline the purpose of conducting the research.
Chapter 2: Theoretical foundations.

This chapter will present the theory of 3D metal printing, including factors and parameters
influencing the process.
Chapter 3: Prototype fabrication study.
In this chapter, the design and fabrication of the prototype will be carried out.
Chapter 4: Sample testing and evaluation.
The steps and methods for testing the sample will be presented before conducting the actual
testing.
Chapter 5: Statistical analysis and evaluation of test results.
This chapter will present the test results and include force diagrams and result evaluations.
Chapter 6: Conclusion.
References.

5


CHAPTER 2: OVERVIEW OF RESEARCH TOPIC
2.1. Overview of additive manufacturing technology
Additive Manufacturing (AM), also known as 3D printing, is a process of building
objects by connecting materials layer by layer based on 3D model data. The process of this
technology can be classified into different types based on fundamental materials such as
plastics, polymers, concrete, metals, and ceramics. The state of the input materials, such as
liquid, molten, powder, and solid layers, can influence the bonding methods of both indirect
and direct processes.
The AM layering process involves a CAD design file and 3D printing software. This
process slices the model of the product into thin layers and guides the material flow to stack
and overlap each layer to create a complete 3D product.

Figure 2. 1 Operating principle of Additive Manufacturing (AM) technology.
Reference source: researchgate.net (2017).
AM technology or 3D printing is currently applied not only for prototyping but also in

many other fields such as shipbuilding, aviation, automotive, biomedical, etc. research and is
considered a promising technology in the future..

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2.2. Classification of AM technology

Figure 2. 2 Methods in Additive Manufacturing (AM) technology.
Reference source: Marwan Khalid (2020).
According to the ASTM 2013 (American Society of Testing and Materials) standard,
there are 7 methods:
Material extrusion: is the technology of extruding materials by the nozzle, the plastic
will melt from the nozzle and dissolve into the metal powder layer to form the design product
shape.
Material Jetting: In this technology, the material will be sprayed onto a flat surface and
solidified in layers, then these layers will be hardened by ultraviolet (UV) light.
Sheet Lamination: is a type of technology that depends on two main processes:
ultrasonic additive manufacturing (UAM) and multi-layer material processing (LOM).
Vat Photopolymer: is an AM additive manufacturing technology that uses
photopolymer fluids to create objects. It is also known as Stereolithography (SLA) or Digital
Light Processing (DLP).
Binding jetting: is a bonding inkjet technology, metal powders will be bonded together
with a liquid binder to create solid details.
Powder Bed Fusion (PBF): is the process that includes DMLS, EBM, SHS, SLM, SLS
technologies. This method uses a laser or an electron beam to melt and melt powdered
materials together
Direct Energy Deposition (DED): Can be understood as Laser metal doposition (LMD)
or Electron beam deposition (EBD) is a type of technology where lasers (or electron beams)
will focus together to create a weld pool on the surface of the product. There, the metal

particles will be heated and bonded together after the welding process.
AM technology has a number of advantages and disadvantages compared to
traditional machining methods:
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Avantages:
 Freelance Design: AM enables the creation of highly detailed and complex shaped
objects that are difficult or impossible to achieve with traditional machining methods.
 Material savings: AM uses material only as needed to create the object, minimizing
material waste compared to traditional cutting machining, where unnecessary cutting
and removal of material is required.
 Time and cost savings: In AM technology, there is no need to prepare molds or
machining tools, and the production process is fully automated. This reduces time and
cost compared to traditional machining, especially for small or custom product batches.
 Diversity of materials: AM additive technology can use a wide range of materials,
including plastics, metals, ceramics, composites and combinations..
Disavantages:
 Production speed: AM typically has a slower production rate than traditional
machining, especially for large and complex objects.
 Accuracy and surface finish: Some AM processes may have less accuracy and surface
finish than traditional machining.
 Object size: AM often limits the object size compared to traditional machining
methods. The size and height of the object is limited by the capabilities of the 3D
printer and the size of the desk.
 Initial investment costs: The initial investment for 3D printers and related equipment
can be significant compared to traditional machining methods. This can increase costs
for businesses new to AM technology.
However, Additive Manufacturing (AM) technology is one of the researched
technologies for almost 40 years and is receiving significant attention due to its ability to

create customized, complex, and material-efficient products while providing flexibility and
accelerating the production process compared to traditional methods. AM combines various
welding technologies such as MIG, MAG, or TIG with robotic arms or CNC machines.
Thanks to the emergence of AM technology, the waste of metal has been significantly reduced
(BTF - Buy To Fly Ratios).
2.3. Some materials used in AM technology
Metal Powders: Metal powders such as aluminum, stainless steel, titanium, copper, zinc,
and many other metals are used for metal AM processes. These metal powders are commonly
used in processes like Direct Metal Laser Sintering (DMLS) or Selective Laser Melting
(SLM).
Metal Wires: Metal wires such as aluminum wire, stainless steel wire, titanium wire,
and nickel-chromium wire (Inconel) can be used in methods like Wire Arc Additive
Manufacturing (WAAM) or Laser Metal Deposition (LMD) to create metal layers.
Metal Rods: Metal rods are also used in metal AM processes. They can be utilized in
processes like Directed Energy Deposition (DED) or Bound Metal Deposition (BMD) to
create metal components.

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Metal Alloys: In addition to pure metal materials, metal alloys are also used to create
metal layers. For example, nickel-titanium alloy (Nitinol) is used in additive manufacturing
processes to create products with shape memory properties.
Metal Fibers: Metal fibers such as stainless steel fibers or carbon fibers can be used in
processes like Fiber Reinforced Metal Matrix Composites (FRMMCs) to reinforce and
improve the mechanical properties of the metal AM products.
In Additive Manufacturing (AM), sheet steel can be used to create metal products. This
process is usually accomplished by overlapping and bonding thin layers of sheet steel to form
a finished product.
2.4. TIG electrodes welding in a protective gas environment

2.4.1. General concept of TIG welding in a protective gas environment
TIG welding (Tungsten Inert Gas Welding) in a shielded gas environment is a welding
method used in industry to join metal materials. During this process, a non-consumable
tungsten electrode is used as the unconnected electrode, and a stream of inactive shielding
gas, usually argon, is used to protect the welding area from air and oxygen.
TIG welding in a shielded gas environment is widely used in many industries, including
machine building, automotive, aviation, metalworking and construction. It is a versatile and
precise welding method that allows high quality welds to be produced on a variety of metal
materials.
Additionally, TIG welding produces clean and visually appealing welds due to the use
of a non-consumable tungsten electrode and an inert shielding gas. The shielding gas,
typically argon, protects the weld pool from atmospheric contamination, resulting in welds
with minimal defects, porosity, and oxidation.

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