Enhancement of Deposition Quality in Micro-plasma Transferred Arc Deposition Process

Jhavar, Suyog; Jain, Neelesh Kumar; Paul, C. P.

doi:10.1080/10426914.2014.892984

Cited by 28 publications

(7 citation statements)

References 16 publications

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“…It also prove that maximum temperature distribution graphs have good accuracy with image processing method. Area of deposition 'Ad' can be calculated assuming shape of the deposition as an elliptical arc as reported and justified by Jhavar et al [14]. Following equation gives its computation details:…”

Section: Prediction Of Dilution By Finite Element Simulationmentioning

confidence: 99%

“…Both the models were validated using the experimental results and found to be good agreement. Jhavar et al [14] developed model to predict cross-section area of deposition geometry obtained by micro-plasma transferred arc wire additive manufacturing (MPTAWAM) process considering profile of deposition geometry as an arc of ellipse. They mentioned that the developed model can be used to optimize the overlap distance between the multi-track deposition.…”

Section: Introductionmentioning

confidence: 99%

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Theoretical modeling and finite element simulation of dilution in micro-plasma transferred arc additive manufacturing of metallic materials

Sawant

Jain

Nikam

2019

International Journal of Mechanical Sciences

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Dilution in any additive layer manufacturing signifies fusion of a deposition layer with the substrate as well as between the successive deposited layers. It assumes importance because it affects metallurgical bonding and properties of the deposited layers. Evaluation of dilution of a deposition by optical microscopy is more accurate but it is destructive due to requirement of the sample preparation. Monitoring and control of the dilution is also very difficult. Dilution can be predicted either by a theoretical model or finite element simulation (FES). This paper presents development of a generic theoretical model and FES to predict dilution of depositions by micro-plasma transferred arc additive manufacturing (MPTAAM) process. The model and FES predicted values were validated by comparing them with the experimental results of single-layer single-track deposition of Ti-6Al-4V powder on the substrate of the same material for the various parametric combinations of MPTAAM process. Results have shown very good agreement between model and FES predicted values of dilution with the corresponding experimental values. The developed theoretical model is also generic because it depends only on the MPTAAM process parameters and thermal properties of the deposition and substratematerials thus making it applicable for any combination of deposition and substrate materials and for any form of the deposition material. The results showed that dilution increases with increase in microplasma power and relative speed between the worktable and deposition head whereas decreases with increase in volumetric feed rate of the deposition material.

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Section: Prediction Of Dilution By Finite Element Simulationmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Theoretical modeling and finite element simulation of dilution in micro-plasma transferred arc additive manufacturing of metallic materials

Sawant

Jain

Nikam

2019

International Journal of Mechanical Sciences

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“…Atmospheric‐pressure plasma jets (PJs) have been attracting great attention in the field of material preparation, biomedicine, and material surface modification because of their simple structure, without spatially bounded by electrodes, and the avoidance of complex vacuum system requirements. In the application of material preparation, plasma wire deposition is a simple and effective method for film deposition, nanomaterial preparation, and additive layer manufacture, in which case a metal wire, used as a source material or precursor, is inserted into plasma. Through the interaction between the plasma and the wire, the metal is etched and/or evaporated in the plasma, and then quickly cools and nucleates in the PJ due to high temperature gradient.…”

Section: Introductionmentioning

confidence: 99%

“…Through the interaction between the plasma and the wire, the metal is etched and/or evaporated in the plasma, and then quickly cools and nucleates in the PJ due to high temperature gradient. Jhavar et al employed the micro‐plasma transferred arc wire deposition for additive layer manufacturing, which was demonstrated to be cost effective, energy efficient, and environmentally friendly, providing a multi‐track‐deposited surface without any defects. Shimizu et al developed a novel method to prepare gold nanoparticles by wire‐spraying employing a room‐temperature atmospheric H 2 /Ar micro‐PJ driven by a pulsing ultrahigh frequency, which is quite different from arc wire deposition .…”

Section: Introductionmentioning

confidence: 99%

Characteristics of an atmospheric‐pressure radio frequency‐driven Ar/H₂ plasma discharge with copperwire in tube

Guo

et al. 2017

Contributions to Plasma Physics

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This paper investigates a plasma discharge driven by a 13.56 MHz radio frequency (RF) power supply at atmospheric pressure, in which a copper wire is inserted in the discharge tube for the deposition of Cu films. The results show that the jet plasma formation originates from the discharge between the copper wire and induction coil because of its electrostatic field. The axial distribution of the plasma parameters in the RF plasma jet, namely the gas temperature, excitation temperature, and electron number density, is determined by diatomic molecule OH fitting, Boltzmann slope, and H Stark broadening, respectively. The discharge current significantly declines when a small amount of hydrogen is added to the argon as the plasma-forming gas, and the gas temperature of discharge plasma increases considerably. KEYWORDS discharge mode, plasma parameters, RF-driven plasma INTRODUCTIONAtmospheric-pressure plasma jets (PJs) have been attracting great attention in the field of material preparation, [1,2] biomedicine, [3,4] and material surface modification [5,6] because of their simple structure, without spatially bounded by electrodes, and the avoidance of complex vacuum system requirements. In the application of material preparation, plasma wire deposition is a simple and effective method for film deposition, [7] nanomaterial preparation, [8] and additive layer manufacture, [9,10] in which case a metal wire, used as a source material or precursor, is inserted into plasma. Through the interaction between the plasma and the wire, the metal is etched and/or evaporated in the plasma, and then quickly cools and nucleates in the PJ due to high temperature gradient. Jhavar et al. [9,10] employed the micro-plasma transferred arc wire deposition for additive layer manufacturing, which was demonstrated to be cost effective, energy efficient, and environmentally friendly, providing a multi-track-deposited surface without any defects. Shimizu et al. developed a novel method to prepare gold nanoparticles by wire-spraying employing a room-temperature atmospheric H 2 /Ar micro-PJ driven by a pulsing ultrahigh frequency, which is quite different from arc wire deposition. [11] We [12][13][14] had also developed a technique for depositing Cu thin films on polyimide by using an RF-driven PJ (RF-PJ) in which a copper wire is set inside a quartz tube as the Cu source. It was demonstrated that this was a novel and successful method for pure Cu thin film deposition, since a high-quality Cu film with relatively high deposition rate could be obtained at a relatively low temperature and in a short residence time in the plasma. In these applications, the characteristics of the plasma are important to understand the interaction between the plasma and the metal wire. For this purpose, the discharge mode and the plasma properties of the RF-PJ with a copper wire in the tube are investigated in this paper. EXPERIMENTAL SET-UPThe schematic diagram of the experimental set-up is shown in Figure 1. The plasma source is structurally identical to an inductive...

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“…Thus, the need for controlled atmosphere and heat affected zone are the short comings micro repair by LENS process. Micro-Plasma-Transferred Arc (µPTA) wire deposition, a newer micro-repair process also suffers from thermal effects [5]. To overcome such shortcomings, a novel electro deposition method using liquid marbles is being developed for micro repair [6].…”

Section: Introductionmentioning

confidence: 99%

Corrosion Study on Liquid Marble Based Localized Electrochemical Deposition on Cold Rolled Steel

Shailendar

Sundaram

2015

Volume 1: Processing

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Application of electrochemical methods for micro repair is being researched. A liquid marble is a liquid droplet coated with hydrophobic micro or nano powders. When the liquid used is a suitable electrolyte, it can be used for localized electrochemical deposition (LECD) which is in turn used for micro repair. Though the feasibility of this process is already established, the properties of the deposit with respect to the metal substrate has to be studied. Corrosion is an important property that can vary between two metals. An immersion corrosion test is performed on a substrates having micro spots made using LECD using 5% NaCl for 240 hours. The results are compared with specimens of the same dimension which underwent the same corrosion testing process. It was found that the micro deposits did not affect the corrosion rate significantly and therefore localized electro deposition using liquid marbles may be considered as a potential method for micro repair.

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Enhancement of Deposition Quality in Micro-plasma Transferred Arc Deposition Process

Cited by 28 publications

References 16 publications

Theoretical modeling and finite element simulation of dilution in micro-plasma transferred arc additive manufacturing of metallic materials

Theoretical modeling and finite element simulation of dilution in micro-plasma transferred arc additive manufacturing of metallic materials

Characteristics of an atmospheric‐pressure radio frequency‐driven Ar/H₂ plasma discharge with copperwire in tube

Corrosion Study on Liquid Marble Based Localized Electrochemical Deposition on Cold Rolled Steel

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Enhancement of Deposition Quality in Micro-plasma Transferred Arc Deposition Process

Cited by 28 publications

References 16 publications

Theoretical modeling and finite element simulation of dilution in micro-plasma transferred arc additive manufacturing of metallic materials

Theoretical modeling and finite element simulation of dilution in micro-plasma transferred arc additive manufacturing of metallic materials

Characteristics of an atmospheric‐pressure radio frequency‐driven Ar/H2 plasma discharge with copperwire in tube

Corrosion Study on Liquid Marble Based Localized Electrochemical Deposition on Cold Rolled Steel

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Characteristics of an atmospheric‐pressure radio frequency‐driven Ar/H₂ plasma discharge with copperwire in tube