Mechanical Analysis of Cu90Ni10 Alloy Processed by Wire Arc Additive Manufacturing using an L9 Orthogonal Array

Abstract

This study focuses on the processing of Cu90Ni10 alloy using Wire Arc Additive Manufacturing (WAAM) and employs an L9 orthogonal array to optimise the mechanical properties of the resulting components. Cu90Ni10 alloy is known for its excellent corrosion resistance and electrical conductivity, making it a critical material in various industries like aerospace and electronics. In this research, a systematic approach based on the L9 orthogonal array is utilised to investigate and optimise the key process parameters of WAAM, such as welding current, Robot/travel speed, gas flow rate and distance between tip and nozzle to achieve desired mechanical properties in the Cu90Ni10 alloy. The L9 orthogonal array is a statistical design of experiments method that enables efficient experimentation with a minimal number of trials, making it a cost-effective and time-saving approach for process optimization. The mechanical properties under consideration include tensile strength, hardness and impact energy. By systematically varying the process parameters according to the L9 orthogonal array design, a comprehensive dataset is generated. The findings of this study contribute to the advancement of Cu90Ni10 alloy processing via WAAM, enabling the production of components with enhanced mechanical performance.