Process parameters optimization for cold metal transfer-deposited IN625 single-layer bead features by entropy weightage-assisted grey-based Taguchi analysis

The selection of the right set of parameters for the desired bead geometry leads to minimize the discontinuous weld bead, weld cracks, porosity, and waviness. The present work focuses on the multi-response optimization for the cold metal transfer-deposited IN625 weld bead characteristics that include bead height, bead width, and penetration depth along with a mechanical property of micro-hardness. Effects of input parameters such as input current, travel speed, and standoff distance are being selected for the investigation by implementing grey relational analysis where entropy weightage method is applied for the calculation of overall grey relation grade. The multi-responses of minimum bead width and maximum bead height, penetration, and microhardness by grey relational analysis are optimized at 140 A current, 4 mm/s travel speed, and 4 mm standoff distance. Confirmatory experiments were also carried out giving the satisfactory validation. The evaluation of bead features optimization can be used for the development of wire arc additive manufacturing process in later stages.