Abstract

Directed Plasma Fabrication (DPF) is a rapid tooling process based on controlled deposition of molten powder particles according to computer controlled patterns. It makes fully dense, near net shape metal components without molds or dies, and without forming, pressing or forging systems.Experimental works were carried out using conventional low current Plasma Transferred Arc Welding system, and metallic powder was stellite #21. Cylindrical shapes were successfully deposited with dimensions of 0.8–1.2mm wall thickness. Critical parameters were plasma current stability and powder supply. Other key factor was the melting efficiency M, which is defined as the ratio of given heat input into base metal and required heat input to melting of deposited metal. The other was is a non dimensional operating parameter, n proposed by N. Christensen. Better deposition efficiency was obtained in case of lower melting efficiency M, this means shorter arc length and slower traveling speed when the same plasma current conditions are applied.

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