TABLE OF CONTENT
Abstrak i
Abstract ii
Dedication iii
Acknowledgement iv
Table of Content v
List of Tables vi
List of Figure vii
CHAPTER 1: INTRODUCTION 1
1.1 Research Background
1 1.2
Problem Statement 2
1.3 Research Objective
3 1.4
Research Scope 3
1.5 Research Organization
4
CHAPTER 2: LITERATURE REVIEW
2.1 Cladding Process
5 2.1.1 Principle of Cladding Process
6 2.1.2 Heat Source for Cladding Process
7 2.1.2.1 Laser Cladding
8
2.1.2.2 Plasma Arc Welding 9
2.1.2.3 Gas Tungsten Arc Welding GTAW 10
2.1.2.4 Gas Metal Arc Welding GMAW 11
2.2 Heat Flow in Cladding Process
11 2.2.1 Rosenthal Three Dimensional 3D Heat Flow
12 2.2.2 Heat Input
13 2.2.2.1 Measure the Heat Input
13 2.2.2.2 Main Factor of Heat Input
14 2.2.2.3 Arc Voltage
15 2.2.2.4 Current
15 2.2.2.5 Travel Speed
16 2.2.2.7 Shielding Gas
16 2.2.3 Effect of Cladding to Heat Input
17 2.2.3.1 Weld Pool Geometry
17 2.2.3.2 Protection of the Weld Pool
18 2.2.3.3 Penetration
18 2.2.3.4 Welded Zone Width
18 2.2.3.5 Melting Efficiency
19 2.3
Cast Iron Substrate 20
2.3.1 Types of Cast Iron 21
2.3.1.1 White Cast Iron 21
2.3.1.2 Grey Cast Iron 21
2.3.2 The Clad of Gray Cast Iron 22
2.4 Cladding Consumables
23
2.4.1 Types of Filler Material for Cladding Cast Iron 23
2.4.1.1 Nickel Based Alloy 23
2.4.1.2 Copper Based Alloy 24
2.4.2 Type of Nickel Based Alloy 25
2.4.2.1 Inconel Alloy 625 25
2.4.2.2 Hastelloy C22 26
2.4.2.3 Tungsten Carbide Reinforced NiCrBSi Alloy 27
2.5 Cladding Metallurgy
30 2.6
Heat and Temperature 30
CHAPTER 3: METHODOLOGY
3.1 Introduction
31 3.2
Statistical Analysis Full Factorial 33
3.3 Variable Machining Parameter
33 3.4
Response Variable 34
3.5 Design of Experiment Matrix
34 3.6
Simulation Smart Weld Software Model 36
3.6.1 Step of Simulation 36
3.6.2 Type of Filler Material in Smart Weld Software 40
3.7 Validation Model
42 3.7.1 Workpiece Preparation
44 3.7.2 Experimental setup
47
CHAPTER 4: RESULT AND DISCUSSION
4.1 Introduction
49 4.2
Design factor 49
4.3 Results for Analysis of Variance ANOVA
for Bead Clad Geometry 55
4.4 Pareto Chart and Normal Plot for Bead Clad Geometry
59 4.5
Main effect for bead clad geometry 63
4.6 Interaction plot for bead clad geometry
66 4.7
Optimization of Response Variable 69
4.8 Discussion
71 4.9
Effect Parameter on Geometry Size 72
CHAPTER 5: CONCLUSION AND FUTURE WORKS RECOMMENDATION
