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Design and Implementation of PLC Based Special Purpose Machine for Surface Coating

Year 2022, Issue: 33, 338 - 343, 31.01.2022
https://doi.org/10.31590/ejosat.1019912

Abstract

To improve the quality and efficiency of surface coating with the GTAW method a semi-automatic welding machine was designed based on PLC control. The control program using ladder logic can accomplish system management and control functions. This system could control welding travel speed up to 560 mm/min, measure and saves the current status of the surface temperature at the welding zone via infrared thermometer up to 1600 °C in real-time, has complete automatic fault diagnosis, modify the welding travel speed and save the inputted welding parameters. To evaluate the performance of the designed welding machine, several experiments have been conducted. An average of 377.5 HV0.2 microhardness was obtained from the surface of SAE (AISI) 1040 materials used in the experiments to a depth of 1 mm via the coating powders containing 64 wt% FeCrC + 16 wt% FeTi and 20 wt% Ni. The results from the experiments have shown that the designed PLC-based semi-automatic welding machine could be effective in determining the optimum conditions for surface coating and different welding processes.

References

  • Alphonsus, E. R., & Abdullah, M. O. (2016). A review on the applications of programmable logic controllers (PLCs). Renewable and Sustainable Energy Reviews, 60, 1185-1205.
  • Amirsadeghi, A., & Sohi, M. H. (2008). Comparison of the influence of molybdenum and chromium TIG surface alloying on the microstructure, hardness and wear resistance of ADI. Journal of materials processing technology, 201(1-3), 673-677.
  • Bartkowski, D., & Bartkowska, A. (2017). Wear resistance in the soil of Stellite-6/WC coatings produced using laser cladding method. International Journal of Refractory Metals and Hard Materials, 64, 20-26.
  • Chang, C. M., Chen, Y. C., & Wu, W. (2010). Microstructural and abrasive characteristics of high carbon Fe–Cr–C hardfacing alloy. Tribology international, 43(5-6), 929-934.
  • Dalmis, S., Teker, T., & Yilmaz, S. O. (2018). Wear behavior of GTA coated FeCrC based bond alloy on an AISI 1040 steel substrate. Kovove Mater, 56, 339-348.
  • Enes, E. F. E., ÖZCAN, M., & HAKLI, H. (2021). Building and Cost Analysis of an Industrial Automation System using Industrial Robots and PLC Integration. Avrupa Bilim ve Teknoloji Dergisi, (28), 1-10.
  • Jankauskas, V., Antonov, M., Varnauskas, V., Skirkus, R., & Goljandin, D. (2015). Effect of WC grain size and content on low stress abrasive wear of manual arc welded hardfacings with low-carbon or stainless steel matrix. Wear, 328, 378-390.
  • Kang, A. S., Grewal, J. S., Jain, D., & Kang, S. (2012). Wear behavior of thermal spray coatings on rotavator blades. Journal of thermal Spray technology, 21(2), 355-359.
  • Kang, A. S., Singh, G., & Cheema, G. S. (2017). Improving wear resistance via hardfacing of cultivator shovel. Materials Today: Proceedings, 4(8), 7991-7999.
  • Kumar, M. K., Saravanan, R., Sellamuthu, R., & Narayanan, V. (2018). Microstructure, hardness and wear rate of heat treated Titanium surface alloyed AISI 304 stainless steel. Materials Today: Proceedings, 5(2), 7571-7576.
  • Kwok, C. T., Cheng, F. T., & Man, H. C. (2000). Laser surface modification of UNS S31603 stainless steel. Part I: microstructures and corrosion characteristics. Materials Science and Engineering: A, 290(1-2), 55-73.
  • Li, A. M., Zhang, C. H., Li, H. L., Xu, Z. Y., Chen, X. H., & Ye, S. W. (2011, March). Design of automatic welding machine based on PLC. Paper presented at Fourth International Conference on Intelligent Computation Technology and Automation (Vol. 1, pp. 627-630). IEEE 2011.
  • Liu, C. L., Ye, J. X., & Niu, S. B. (2019). Automatic welding system design for transformer station grounding steel based on PLC. In IOP Conference Series: Materials Science and Engineering (Vol. 504, No. 1, p. 012099). IOP Publishing.
  • Mithun, C. M., Sellamuthu, R., & Saravanan, R. (2018). Effect of surface modification on microstructure, hardness and wear rate of steels with 0.2%, 0.4% and 1.1 Wt% C by the addition of Titanium using Gas Tungsten Arc. Materials Today: Proceedings, 5(2), 7586-7594.
  • Nair, S., Sellamuthu, R., & Saravanan, R. (2018). Effect of Nickel content on hardness and wear rate of surface modified cast aluminum bronze alloy. Materials Today: Proceedings, 5(2), 6617-6625.
  • Patil, K. V., Gadade, B. K., Raut, P. G., Gaikwad, S. K., & Toke, G. A Novel approach of MIG Welding using PLC. IJAREEIE–2014.
  • Rullán, A. (1997). Programmable logic controllers versus personal computers for process control. Computers & industrial engineering, 33(1-2), 421-424.
  • Selvi, S., Sankaran, S. P., & Srivatsavan, R. (2008). Comparative study of hardfacing of valve seat ring using MMAW process. Journal of materials Processing technology, 207(1-3), 356-362.
  • Shanmugasundaram, A., Arul, S., & Sellamuthu, R. (2018). Study on the Effect of GTA Surface Melting and SiC Reinforcement on the Hardness, Wear and Corrosion Properties of AA 5086. Materials Today: Proceedings, 5(2), 6597-6606.
  • Taysom, B. S., & Sorensen, C. D. (2020). Controlling martensite and pearlite formation with cooling rate and temperature control in rotary friction welding. International Journal of Machine Tools and Manufacture, 150, 103512.
  • Ya-long, L., Tian-shun, D., Guo-lu, L., Hai-dou, W., Bin-Guo, F., Xiao-dong, Z., & Xiu-kai, Z. (2018). Microstructure and mechanical property of Ni-based thick coating remelted by gas tungsten arc. Vacuum, 155, 260-269.
  • Yang, Z. Z., Hao, H., Gao, Q., Cao, Y. B., Han, R. H., & Qi, H. B. (2020). Strengthening mechanism and high-temperature properties of H13+ WC/Y2O3 laser-cladding coatings. Surface and Coatings Technology, 126544.
  • Yufeng, S., Sili, F., & Changwei, X. (2018). Optimization of welding process of heterogeneous high strength steel based on PLC control. Results in Physics, 11, 817-820.

Yüzey Kaplama için PLC Tabanlı Özel Amaçlı Makina Tasarımı ve Uygulaması

Year 2022, Issue: 33, 338 - 343, 31.01.2022
https://doi.org/10.31590/ejosat.1019912

Abstract

GTAW yöntemi ile yüzey kaplamanın kalitesini ve verimliliğini artırmak için PLC kontrollü yarı otomatik bir kaynak makinesi tasarlanmıştır. Ladder mantığını kullanan kontrol programı, sistem yönetimi ve kontrol fonksiyonlarını gerçekleştirebilir. Bu sistem, 560 mm/dk'ya kadar kaynak hareket hızını kontrol edebilir, gerçek zamanlı olarak 1600 °C'ye kadar kızılötesi termometre ile kaynak bölgesindeki yüzey sıcaklığının mevcut durumunu ölçer ve kaydeder, tam otomatik arıza teşhisine sahiptir, kaynak ilerleme hızını düzenler ve girilen kaynak parametrelerini kaydedebilir. Tasarlanan kaynak makinesinin performansını değerlendirmek için çeşitli deneyler yapılmıştır. Deneylerde kullanılan SAE (AISI) 1040 malzemelerinin yüzeyinden ağırlıkça %64 FeCrC + ağırlıkça %16 FeTi ve ağırlıkça %20 Ni içeren kaplama tozları ile ortalama 377.5 HV0.2 mikrosertlik elde edilmiştir. Deneylerden elde edilen sonuçlar, tasarlanan PLC tabanlı yarı otomatik kaynak makinesinin, yüzey kaplama ve farklı kaynak işlemleri için optimum koşulların belirlenmesinde etkili olabileceğini göstermiştir.

References

  • Alphonsus, E. R., & Abdullah, M. O. (2016). A review on the applications of programmable logic controllers (PLCs). Renewable and Sustainable Energy Reviews, 60, 1185-1205.
  • Amirsadeghi, A., & Sohi, M. H. (2008). Comparison of the influence of molybdenum and chromium TIG surface alloying on the microstructure, hardness and wear resistance of ADI. Journal of materials processing technology, 201(1-3), 673-677.
  • Bartkowski, D., & Bartkowska, A. (2017). Wear resistance in the soil of Stellite-6/WC coatings produced using laser cladding method. International Journal of Refractory Metals and Hard Materials, 64, 20-26.
  • Chang, C. M., Chen, Y. C., & Wu, W. (2010). Microstructural and abrasive characteristics of high carbon Fe–Cr–C hardfacing alloy. Tribology international, 43(5-6), 929-934.
  • Dalmis, S., Teker, T., & Yilmaz, S. O. (2018). Wear behavior of GTA coated FeCrC based bond alloy on an AISI 1040 steel substrate. Kovove Mater, 56, 339-348.
  • Enes, E. F. E., ÖZCAN, M., & HAKLI, H. (2021). Building and Cost Analysis of an Industrial Automation System using Industrial Robots and PLC Integration. Avrupa Bilim ve Teknoloji Dergisi, (28), 1-10.
  • Jankauskas, V., Antonov, M., Varnauskas, V., Skirkus, R., & Goljandin, D. (2015). Effect of WC grain size and content on low stress abrasive wear of manual arc welded hardfacings with low-carbon or stainless steel matrix. Wear, 328, 378-390.
  • Kang, A. S., Grewal, J. S., Jain, D., & Kang, S. (2012). Wear behavior of thermal spray coatings on rotavator blades. Journal of thermal Spray technology, 21(2), 355-359.
  • Kang, A. S., Singh, G., & Cheema, G. S. (2017). Improving wear resistance via hardfacing of cultivator shovel. Materials Today: Proceedings, 4(8), 7991-7999.
  • Kumar, M. K., Saravanan, R., Sellamuthu, R., & Narayanan, V. (2018). Microstructure, hardness and wear rate of heat treated Titanium surface alloyed AISI 304 stainless steel. Materials Today: Proceedings, 5(2), 7571-7576.
  • Kwok, C. T., Cheng, F. T., & Man, H. C. (2000). Laser surface modification of UNS S31603 stainless steel. Part I: microstructures and corrosion characteristics. Materials Science and Engineering: A, 290(1-2), 55-73.
  • Li, A. M., Zhang, C. H., Li, H. L., Xu, Z. Y., Chen, X. H., & Ye, S. W. (2011, March). Design of automatic welding machine based on PLC. Paper presented at Fourth International Conference on Intelligent Computation Technology and Automation (Vol. 1, pp. 627-630). IEEE 2011.
  • Liu, C. L., Ye, J. X., & Niu, S. B. (2019). Automatic welding system design for transformer station grounding steel based on PLC. In IOP Conference Series: Materials Science and Engineering (Vol. 504, No. 1, p. 012099). IOP Publishing.
  • Mithun, C. M., Sellamuthu, R., & Saravanan, R. (2018). Effect of surface modification on microstructure, hardness and wear rate of steels with 0.2%, 0.4% and 1.1 Wt% C by the addition of Titanium using Gas Tungsten Arc. Materials Today: Proceedings, 5(2), 7586-7594.
  • Nair, S., Sellamuthu, R., & Saravanan, R. (2018). Effect of Nickel content on hardness and wear rate of surface modified cast aluminum bronze alloy. Materials Today: Proceedings, 5(2), 6617-6625.
  • Patil, K. V., Gadade, B. K., Raut, P. G., Gaikwad, S. K., & Toke, G. A Novel approach of MIG Welding using PLC. IJAREEIE–2014.
  • Rullán, A. (1997). Programmable logic controllers versus personal computers for process control. Computers & industrial engineering, 33(1-2), 421-424.
  • Selvi, S., Sankaran, S. P., & Srivatsavan, R. (2008). Comparative study of hardfacing of valve seat ring using MMAW process. Journal of materials Processing technology, 207(1-3), 356-362.
  • Shanmugasundaram, A., Arul, S., & Sellamuthu, R. (2018). Study on the Effect of GTA Surface Melting and SiC Reinforcement on the Hardness, Wear and Corrosion Properties of AA 5086. Materials Today: Proceedings, 5(2), 6597-6606.
  • Taysom, B. S., & Sorensen, C. D. (2020). Controlling martensite and pearlite formation with cooling rate and temperature control in rotary friction welding. International Journal of Machine Tools and Manufacture, 150, 103512.
  • Ya-long, L., Tian-shun, D., Guo-lu, L., Hai-dou, W., Bin-Guo, F., Xiao-dong, Z., & Xiu-kai, Z. (2018). Microstructure and mechanical property of Ni-based thick coating remelted by gas tungsten arc. Vacuum, 155, 260-269.
  • Yang, Z. Z., Hao, H., Gao, Q., Cao, Y. B., Han, R. H., & Qi, H. B. (2020). Strengthening mechanism and high-temperature properties of H13+ WC/Y2O3 laser-cladding coatings. Surface and Coatings Technology, 126544.
  • Yufeng, S., Sili, F., & Changwei, X. (2018). Optimization of welding process of heterogeneous high strength steel based on PLC control. Results in Physics, 11, 817-820.
There are 23 citations in total.

Details

Primary Language English
Subjects Engineering
Journal Section Articles
Authors

Kenan Can 0000-0003-1770-1180

Figan Dalmış 0000-0001-6841-3467

İbrahim Dalmış 0000-0002-4401-9155

Early Pub Date January 30, 2022
Publication Date January 31, 2022
Published in Issue Year 2022 Issue: 33

Cite

APA Can, K., Dalmış, F., & Dalmış, İ. (2022). Design and Implementation of PLC Based Special Purpose Machine for Surface Coating. Avrupa Bilim Ve Teknoloji Dergisi(33), 338-343. https://doi.org/10.31590/ejosat.1019912