Some studies on optimization of process parameters for wire ARC additive manufacturing of Hastelloy C276 using GRA-GWO hybrid techniques

Wire arc additive manufacturing (WAAM) has become an inevitable manufacturing technology in the present decade. This article discusses optimizing process variables for fabricating Hastelloy C276 alloy via WAAM. The controlling parameters are gas flow rate (GFR), deposition speed, and welding current, while the depth of penetration, top reinforcement, and bead width are the output parameters considered for optimization. The magnitude of interaction effects between control parameters is equal to that of individual impact on the weld bead characteristics evident from analysis of variance results. Grey relational analysis revealed the optimal parameters (trial 1 with I = 120 A, S = 200 mm/min, GFR = 15 L/min) chosen through its robust optimization procedure. S/N ratio analysis revealed the most influencing parameters at the factor level (current level 1, speed level 1). The Grey Wolf optimizer (GWO) algorithm was used as a precision and confirmation experiment. The GWO optimization results further confirmed that the GFR of 15 L/min, speed of 200 mm/min, and current of 120 A were the optimized parameters used in this design space. Further, normal probability plots with minimal error of around 1% reinforce that the parameters chosen in this design space are well within the optimal limits. The surface plots reported the relationship and variation between control and resulting factors.