Abstract
This study examines simulative experimental investigations on the additive manufacturing of complex component geometries using 3D plasma metal deposition (3DPMD). Here, complex contour surfaces for a cross-rolling tool were produced from weld metals in multilayer technology through 3DPMD. As a consequence of the special features of 3DPMD with large-weld metal volumes, greatly differing properties between base material/deposited material and asymmetrical heat input, the resulting shrinkage, deformation and residual stresses are particularly critical. These lead to dimensional and form deviations as well as the formation of cracks, which has a negative influence on the quality of the plasma deposition-welded component structures. By means of the thermo-elastic-plastic simulation model, the temperature field distribution, deformation, and residual stresses occurring during additive 3DPMD of tool contours were predicted and analyzed. The temperature field distribution and its gradients were determined using the ellipsoid heat-source model for the 3DPMD process. On this basis, a coupled thermo-elastic-plastic structural–mechanical analysis was performed. Accordingly, the results achieved were used for the production of almost-net-shaped tool contour surfaces with predefined layer properties. The acquired simulation results of the temperature fields, deformation, and residual stress condition show good alignment with the experimental results.
Highlights
The sophisticated additive manufacturing technology for processing metallic materials by means of 3D plasma metal deposition (3DPMD) from pure large-weld metal volumes is establishing itself as a new manufacturing process
A lot of processes are used in wire arc additive manufacturing (WAAM) for e.g., metal inert gas (MIG), CMT, tungsten inert gas (TIG), etc
For verification of the finite element (FE) model, measurements were performed on the deposited welded specimens with regard to the temperature field distributions, weld deformations, and residual stresses
Summary
The sophisticated additive manufacturing technology for processing metallic materials by means of 3D plasma metal deposition (3DPMD) from pure large-weld metal volumes is establishing itself as a new manufacturing process. By mixing several powders in an arc, the local properties of the added layer can be adapted to the defined service loads, locally and partially With this technology, a minimum thermal load on the deposit and base materials is achieved; in addition, a reliable and reproducible layer quality is guaranteed [11,12,13]. The cross-rolling tool contour surfaces were produced using 3DPMD with predefined layer properties. This tool is subject to complex thermomechanical loads/stresses. Based on the knowledge gained, an additive 3DPMD strategy for the production of a cross-rolling tool with functional surface properties, e.g., wear and temperature resistance by the effect of the workpiece, was developed and implemented in practice. Approach–Development of Innovative Three-Dimensional Plasma Metal Deposition (3DPMD) Technology
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