A simplified modelling approach for thermal behaviour analysis in hybrid plasma arc-laser additive manufacturing

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dc.contributor.authorWang, Chong
dc.contributor.authorSun, Yongle
dc.contributor.authorChen, Guangyu
dc.contributor.authorChen, Xin
dc.contributor.authorDing, Jialuo
dc.contributor.authorSuder, Wojciech
dc.contributor.authorDiao, Chenglei
dc.contributor.authorWilliams, Stewart
dc.date.accessioned2022-06-30T11:04:54Z
dc.date.available2022-06-30T11:04:54Z
dc.date.issued2022-06-25
dc.description.abstractHybrid plasma transferred arc (PTA)-laser additive manufacturing (AM) has the potential to build large-scale metal components with high deposition rate and near-net shape. However, the process is complex with many parameters adjustable for process control, which determine the thermal behaviour and thus the final structure and properties of the deposited components. In this study, a three-dimensional steady-state finite element model with two independent circular surface heat sources was developed, validated, and used to analyse the thermal behaviour in hybrid PTA-laser AM of Ti-6Al-4V. Artificial conductivity in three orthogonal directions was applied in the melt pool to compensate for the melt pool convection effect. The predicted melt pool geometry, heat-affected zone and thermal cycles had good agreement with the corresponding experimental data. This model has advantages over the widely used volumetric heat source model, since it is more representative of the energy sources used, giving accurate thermal prediction for a wide range of process parameters. As the heat source parameters in this model are directly linked to the actual arc/laser size, it enables to capture heat source size effect on the hybrid process. In addition, it is easier to calibrate compared to the model with volumetric heat sources due to the fewer empirical parameters involved. It was found that in the investigated ranges of all the parameters, the melt pool geometry is more sensitive to laser power and travel speed compared to arc-laser separation distance and laser beam size. The full-field distributions of the cooling rate and temperature gradient in the hybrid process were obtained and the roles that different process parameters played on them were also studied, which provided useful thermal information for metallurgical analysis.en_UK
dc.identifier.citationWang C, Sun Y, Chen G, et al., (2022) A simplified modelling approach for thermal behaviour analysis in hybrid plasma arc-laser additive manufacturing. International Journal of Heat and Mass Transfer, Volume 195, October 2022, Article number 123157en_UK
dc.identifier.issn0017-9310
dc.identifier.urihttps://doi.org/10.1016/j.ijheatmasstransfer.2022.123157
dc.identifier.urihttps://dspace.lib.cranfield.ac.uk/handle/1826/18105
dc.language.isoenen_UK
dc.publisherElsevieren_UK
dc.rightsAttribution 4.0 International*
dc.rights.urihttp://creativecommons.org/licenses/by/4.0/*
dc.subjectHybrid plasma arc-laser additive manufacturingen_UK
dc.subjectSteady-state finite element modelen_UK
dc.subjectOrthotropic artificial conductivityen_UK
dc.subjectMelt pool geometryen_UK
dc.subjectThermal variablesen_UK
dc.titleA simplified modelling approach for thermal behaviour analysis in hybrid plasma arc-laser additive manufacturingen_UK
dc.typeArticleen_UK

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