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

1
Steinbeis Innovation Center Intelligent Functional Materials, Welding and Joining Techniques, Implementation, Manfred-von-Ardenne-Ring 20, 01099 Dresden, Germany
2
Chair of Welding Engineering, Chemnitz University of Technology, Reichenhainer Strasse 70, 09126 Chemnitz, Germany
*
Author to whom correspondence should be addressed.
Metals 2019, 9(5), 574; https://doi.org/10.3390/met9050574
Received: 18 April 2019 / Revised: 13 May 2019 / Accepted: 15 May 2019 / Published: 17 May 2019
(This article belongs to the Special Issue Arc-based Additive Manufacturing)
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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. View Full-Text
Keywords: additive manufacturing; 3DPMD; filler materials; tool model; FE model; simulation; warpage and residual stresses; temperature fields; heat source model additive manufacturing; 3DPMD; filler materials; tool model; FE model; simulation; warpage and residual stresses; temperature fields; heat source model
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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited (CC BY 4.0).
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Alaluss, K.; Mayr, P. Additive Manufacturing of Complex Components through 3D Plasma Metal Deposition—A Simulative Approach. Metals 2019, 9, 574.

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