Micro-Plasma Transferred Arc Additive Manufacturing for Die and Mold Surface Remanufacturing

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

doi:10.1007/s11837-016-1932-z

Cited by 42 publications

(9 citation statements)

References 14 publications

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“…On dies and moulds, during their use, different types of defects, such as heat cracks and wear, could occur [78], and for this reason, they have a limited in-service lifetime [79]. One of the most challenging issues during the repair operation of dies and tools is related to the low weldability of the materials commonly used for their production [80]. In addition, due to the high carbon content and alloying elements, there is a high tendency to the formation of brittle phases [81].…”

Section: Lp-ded Repair Of Tools and Mouldsmentioning

confidence: 99%

“…In addition to the feasibility of the repair operation, a lot of works were focused on the sustainability and the environmental impact that derives from repair operation. The sustainability and the environmental impact were measured by different factors such as energy consumption, pollution, material waste, lead time, and cost [79,80,[88][89][90]. The impact of these factors is usually investigated by Life Cycle Analysis (LCA) [91].…”

Section: Lp-ded Repair Of Tools and Mouldsmentioning

confidence: 99%

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Current research and industrial application of laser powder directed energy deposition

Piscopo

Iuliano

2022

Int J Adv Manuf Technol

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Additive Manufacturing (AM) technologies are recognized as the future of the manufacturing industry thanks to their possibilities in terms of shape design, part functionality, and material efficiency. The use of AM technologies in many industrial sectors is growing, also due to the increasing knowledge regarding the AM processes and the characteristics of the final part. One of the most promising AM techniques is the Directed Energy Deposition (DED) that uses a thermal source to generate a melt pool on a substrate into which metal powder is injected. The potentialities of DED technology are the ability to process large build volumes (> 1000 mm in size), the ability to deliver the material directly into the melt pool, the possibility to repair existing parts, and the opportunity to change the material during the building process, thus creating functionally graded material. In this paper, a review of the industrial applications of Laser Powder Directed Energy Deposition (LP-DED) is presented. Three main applications are identified in repairing, designed material, and production. Despite the enormous advantages of LP-DED, from the literature, it emerges that the most relevant application refers to the repairing process of high-value components.

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Section: Lp-ded Repair Of Tools and Mouldsmentioning

confidence: 99%

Section: Lp-ded Repair Of Tools and Mouldsmentioning

confidence: 99%

Current research and industrial application of laser powder directed energy deposition

Piscopo

Iuliano

2022

Int J Adv Manuf Technol

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“…Therefore, the interest in microarcs is related to modern applications. Powerful but small‐sized sources can be used for melting the workpiece in additive manufacturing and for repair and re‐manufacturing of high‐value components and damaged surfaces, [ 4 ] microwelding, [ 5 ] and production of bio‐active coatings by microarc oxidation of titanium and zirconium [ 6,7 ] among others. No less than the various applications, basic research on microarcs is also hugely important.…”

Section: Introductionmentioning

confidence: 99%

Plasma parameters of microarcs towards minuscule discharge gap

Baeva

Loffhagen

Becker

et al. 2020

Contributions to Plasma Physics

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This paper describes the behaviour of the plasma parameters of microarcs generated between a cooled copper anode and a ceriated tungsten cathode by means of a one-dimensional unified non-equilibrium model for gap lengths between 15 and 200 μm and current densities from 2 × 10 5 up to 10 6 A/m 2. The results obtained show that the decrease of the gap length to a few tens of micrometres for a given current density results in a progressive shrinking of the quasi-neutral bulk in the microplasma and its complete disappearance. The decrease of the gap length further leads to an increase of the discharge voltage and the electron temperature and to slightly less heating of the gas.

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“…FC300 castings are often repaired via gas-welding processes owing to the relatively low processing temperatures involved. 6–10 However, when using gas-welding as well, great care must be taken to minimize the number of defects caused by prolonged heating of the material. In particular, the rapid heating and subsequent cooling that occurs during the welding process may induce phase transformations within the base metal and welded zone to form white cast iron.…”

Section: Introductionmentioning

confidence: 99%

Characterization of mechanical behavior in repaired FC300 using directly deposited AISI-P21 and AISI-H13 metal powders

Lee

Shim

et al. 2019

Proceedings of the Institution of Mechanical Engineers, Part B:

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Remanufacturing is a promising technique for reducing manufacturing costs and material usage. This work presents a method for repairing casting parts using an additive metal-layer deposition process. To determine characteristics and mechanical properties of parts repaired using the proposed additive metal-layer-deposition-based method, tensile specimens were designed with grooves measuring 1 mm and 3 mm in depth. Two specific metal powders, AISI-P21 (SCM440) and AISI-H13 (SKD61), were melted using a highly focused laser, and molten droplets were subsequently built up layer-by-layer to fill-in the grooves. Mechanical and metallurgical characteristics of repaired parts were investigated via tensile and hardness tests and microstructural analyses. Experimental results demonstrate that the ultimate strength of specimens repaired using the proposed additive metal-layer deposition method measured approximately 9% lower compared with that of FC300. However, the mechanical strength of additive metal-layer deposition specimen was increased about 22% compared with that of welded specimen. Through this work, we can make a conclusion that the additive metal-layer deposition technique is well-suited for the repair and reproduction of castings.

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Micro-Plasma Transferred Arc Additive Manufacturing for Die and Mold Surface Remanufacturing

Cited by 42 publications

References 14 publications

Current research and industrial application of laser powder directed energy deposition

Current research and industrial application of laser powder directed energy deposition

Plasma parameters of microarcs towards minuscule discharge gap

Characterization of mechanical behavior in repaired FC300 using directly deposited AISI-P21 and AISI-H13 metal powders

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