Abstract
The additive manufacturing of components is characterized by a layered build-up. The stability of the build-up process with regard to the component geometry and the layer thickness is essential for the success of the entire system. A prerequisite for this is the exact knowledge of the interrelationships between the process, construction parameters and the resulting component geometry, respectively. These correlations are determined within the study using the 3D Plasma Metal Deposition Process (3DPMD). For this purpose, the process is first subjected to a system analysis. Possible influencing variables were identified with regard to the question “Which system parameters influence the component geometry?” and then prioritized. Then, the influence of control factors (welding current intensity, welding speed, and powder mass flow) was investigated according to the specifications of the Design of Experiments (DOE) method by means of a full-factorial experimental design and evaluated on the basis of metallographic cross-sections. As a result, it was determined that the system parameter powder mass flow only influences the layer thickness and not the wall thickness and is, therefore, available as a process control variable. In sum, comprehensive knowledge of complex relationships between the control parameters and the component geometry in additive manufacturing using 3DPMD was achieved and forms the basis for further scientific work.
Highlights
The layer-by-layer design of components made of shapeless raw material is known as additive manufacturing [1]
The influence of the control factors on the respective geometry parameter is shown in standardized form, with the low level of the control factor always being taken as the reference value (≡1.0)
The results of the evaluation show that, as the welding current decreases, the layer thickness increases while the wall thickness decreases (Figure 3)
Summary
The layer-by-layer design of components made of shapeless raw material is known as additive manufacturing [1]. The 3DPMD process is based on the classic PTA [3,4,5] The conventional aim of the PTA process is to enhance the resistance of the component surface to aggressive media, corrosion, abrasion or to replace missing material [6,7]. For this purpose, several welding beads are usually applied to the base material in three to five layers similar to a carpet. Any deviations in the resulting bead width or weld seam height do not have a significant effect on the coating or the process quality and are, of minor importance
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