Effects of Pulse Interval on Forming Process in Wire Arc Metal Additive Manufacturing Using Pulsed Arc Plasma

Area of Science:

• Materials Science
• Manufacturing Engineering
• Plasma Physics

Background:

• Wire arc additive manufacturing (WAAM) faces challenges with high heat input.
• Pulsed arc plasma WAAM (PAP-WAAM) was developed to mitigate these issues.
• The effect of pulse interval on PAP-WAAM forming processes remains uninvestigated.

Purpose of the Study:

• To investigate the effects of pulse interval on the thermal behavior, arc plasma characteristics, and metal transfer during Ti6Al4V PAP-WAAM.
• To understand how varying pulse intervals influence the heat accumulation and deposition quality.
• To establish optimal pulse intervals for improved WAAM fabrication.

Main Methods:

• Experimental investigation of PAP-WAAM process parameters.
• Computational simulation to analyze thermal behavior and plasma characteristics.
• Analysis of metal transfer modes and resulting part macrostructure.

Main Results:

• Increasing pulse interval decreases interpass and peak temperatures, reducing heat accumulation.
• Longer pulse intervals shift arc ignition to the filler wire, optimizing energy allocation and reducing overall heat input.
• Uninterrupted bridging transfer mode observed at 300-400 ms pulse intervals, leading to smoother layers.
• Reduced surface oxidation, narrower wall thickness, and improved macrostructure with longer pulse intervals.

Conclusions:

• Pulse interval is a critical parameter for controlling heat input and forming processes in PAP-WAAM.
• Optimized pulse intervals enhance thermal management, material transfer, and part quality for Ti6Al4V.
• This study provides insights for fabricating superior metal parts using PAP-WAAM.