A simulation approach for series production of plasma-based additive manufacturing of Ti-6Al-4V components

Abstract

Plasma Metal Deposition (PMD®) is a variant of a directed energy deposition (DED) process that uses an arc welding process to additively manufacture metal components. This process is characterised by relatively high deposition rates, low restrictions regarding the build space, low investment, and operating costs, and is, therefore, predestined for the series production of large structural parts. Additionally, advances in machine development, path planning, and the use of structural welding simulations are bringing these additive manufacturing (AM) technologies into the focus of modern production strategies. To ensure the quality of additively manufactured components in an exactly reproducible manner is, however, a challenge. This requires the complete reproducibility of the manufacturing process and the materials used. This paper investigates the Plasma Metal Deposition manufacturing process of a small batch of Ti-6Al-4V components. Numerical approaches for predicting temperature fields, distortions and residual stresses are examined using the Finite Element (FE) software Simufact Welding 8.0. The focus of the investigations is on the numerical analysis of the influence of the manufacturing process on the mechanical behaviour for multi-layer components. As an outstanding example, the manufacturing of an aerospace bracket is presented.