Additive Manufacturing of Complex Components through 3D Plasma Metal Deposition—A Simulative Approach

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.

Plasma-arc technologies of additive surfacing (3D printing) of spatial metal products: application experience and new opportunities

“…In [12], the principle possibility of using plasma-arc (microplasma) with a pulsed current for 3D printing of steel volumetric metal products with sufficient geometric detailing was also confirmed. At the same time, the grains of the deposited layers change their structure from a relatively small grain size near the substrate to a very coarse structure with a large grain size near the apex of a product.…”

“…at the same time, as a material for 3D printing, the possibility of using steel shot with a size of about 1 mm is shown. however, in the case of using such a filler material by the method of microplasma surfacing, the productivity is low (of about 50 g/h) in the case of control of product temperature and cooling after each layer during a certain waiting time [12]. such an approach allows adjusting the grain size and hardness of printed volumetric steel products.…”

Improving the Mechanical Strength of Dental Applications and Lattice Structures SLM Processed

“…Some laser parameters for stable or relatively stable processability can be seen in Table 4. by temperature gradient mechanism [15,34,39]. Based on this metallurgical behavior, pre-solidified material underneath the melted layer is heated up rapidly upon laser irradiation, which readily expands, but is constricted by the cold and rigid portions of the solidified piece, repeated in multiple cycles [40,41].…”

Control of starch–lipid interactions on starch digestibility during hot-extrusion 3D printing for starchy foods

“…HE-3DP includes three core stages: the heating process of the printing barrel, the extrusion process through the nozzle, and the cooling and deposition process after printing. 3 In HE-3DP, the food material is produced by a hydrothermal reaction; meanwhile, the kinetic energy of the molecular chain increases, and the original microstructure disintegrates to form a new mixed system. 4 Then, the food ink is squeezed out of the narrow nozzle because of the strong shear effect, and the microstructure of the material undergoes orientation and rearrangement, changing the multiscale structure and thus endowing new characteristics, including processing properties and nutrition functions.…”