The purpose of this research is to study the influence of the processing conditions that affect the final behaviour of specimens made from a 17-4PH composition powder without the necessary thermal treatment to be considered 17-4PH, which is manufactured using the additive technique known as plasma metal deposition (PMD). To that end, two walls manufactured from the prealloyed powder were built under two distinct atmospheric conditions, i.e., air and argon, with previously optimized manufacturing parameters. The additional effect of two applied thermal treatments (TT) was studied by means of property and microstructural analyses of the extracted specimens from each consolidated wall. The two thermal treatments consisted of a heating rate of 10 °C/min to 482 °C (TT1) and 620 °C (TT2), with the temperatures for 1 and 4 h, respectively; the cooling rate was 5 °C/min for both treatments. According to the findings, the presence of an argon atmosphere during manufacturing promoted the presence of an austenite phase, reducing the deformation of the samples and enhancing their Young’s modulus. The TT1 treatment positively contributed, improving the mechanical properties in general, and TT2 substantially improved the elongation in both sets of specimens.
Arc-directed energy deposition using wire as feedstock is establishing itself as a 3D printing method capable of obtaining additively manufactured large structures. Contrasting results are reported in the literature about the effect of the deposition parameters on the quality of the deposited tracks, as it is highly dependent on the relationship and intercorrelations between the individual input parameters, which are generally deposition-technique-dependent. This study comprehensively analysed the effect of several deposition parameters and clarified their interactions in plasma metal deposition of Al alloys. It was found that, although no straightforward correlation between the individual input parameters investigated and the measured output deposition track’s quality aspects existed, the input current had the greatest effect, followed by the wire feed speed and its interaction with the input current. Moreover, the greatest effect of changing the shielding gas atmosphere, including the gas mixture, flow rate and plasma flow, was on the penetration depth, and fine-tuning the frequency/balance ratio and the preheating of the deposition substrates reduced the amount of porosity. This study demonstrates that well-deposited multi-layer walls made out of Al alloys can successfully be achieved via plasma metal deposition.
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