This paper attempts to apply microplasma powder deposition (MPPD) for solid freeform fabrication (SFF). The relationship between the geometric features of the deposited layers and the welding parameters is investigated. The arc length is controlled through the monitoring of arc voltage. The microstructure and the properties of the deposited layers are analysed. The experimental results show that the MPPD process is a promising welding-based SFF technology that is capable of building relatively small-size parts with low cost. The result of building parts with functionally graded components by the MPPD process is shown as well.
BeamanJ. J.BarlowJ. W.BourellR. H.CrafordH. L.MarcusH. L.McAleaK. P.Solid Freeform Fabrication: A New Development in Manufacturing, 1997 (Kluwer Academic Publishers, Dordrecht, Boston and London).
2.
KovacevicR.Rapid manufacturing of functional parts based on deposition by welding and 3D laser cladding. In Proceedings of the Maold Making 2001 Conference, Rose-mont, Illinois, 3–5 April 2001, pp. 263–276.
3.
KassmaulK.SchochF. W.LucknowH.High quality large components 'shape welded' by a SAW process. Weld. J., September 1983.
4.
PiehlK.-H.Formgebendes SchweiBen von Schwekomponenten. Company Report, Thyssen Aktiengesellschaft, Duisburg, Germany, January 1989.
5.
DoyleT. E.(Babcock and Wilcox) Shape melting technology. In Third International Conference on Desktop Manufacturing: Making Rapid Prototyping Pay Back, The Management Round Table, October 1991.
6.
DickensP. M.CobbR.GibsonI.PridbamM. S.Rapid prototyping using 3D welding. J. Des. Mfg, 1993, 3.
7.
RibeiroA. F.NorrishJ.Metal based rapid prototyping for more complex shapes. In 6th Biennial Conference on Computer Technology in Welding, Lanaken, Belgium, 9–12 June 1996 (TWI, Abington Publishing).
8.
RibeiroA. F.NorrishJ.Rapid prototyping process using metal directly. In Proceedings of the 7th Annual Solid Freeform Fabrication Symposium, Austin, Texas, 12–14 August 1996.
9.
RibeiroA. F.NorrishJ.Making components with controlled metal deposition. In IEEE International Symposium on Industrial Electronics, Guimaraes, Portugal, 7–11 July 1997.
10.
KovacevicR.BeardsleyH. E.Process control of 3D welding as a droplet-based rapid prototyping technique. In Proceedings of the 9th Annual Solid Freeform Fabrication Symposium, Austin, Texas, 10–12 August 1998.
11.
WangH.KovacevicR.Rapid prototyping based on variable polarity gas tungsten arc welding for 5356 aluminum alloys. Proc. Instn Mech. Engrs, Part B: J. Engineering Manufacture, November 2001, 215(B11), 1519–1527.
12.
JandricZ.KovacevicR.New way of process parameters optimization in SFF based on deposition by welding. In Proceedings of the 12th Annual Solid Freeform Fabrication Symposium, Austin, Texas, 6–8 August 2001, pp. 110–119.
13.
SongY.ParkS.HwangK.ChoiD.JeeH.3D welding and milling for direct prototyping of metallic parts. In Proceedings of the 9th Annual Solid Freeform Fabrication Symposium, Austin, Texas, 10–12 August 1998.
14.
KarunakaranK.ShanmuganathanP.Roth-KochS.KochU.Direct rapid prototyping of tools. In Proceedings of the 9th Annual Solid Freeform Fabrication Symposium, Austin, Texas, 10–12 August 1998.
MatthesK.-J.AlalussK.Plasma-arc powder surfacing with pulsed arc for minimum deformation shaping. Schweissen und Schneiden/Welding and Cutting, September 1996, 48(9), E170–E172.
17.
MatthesK.-J.AlalussK.KhaledF.Utilisation of the finite-element method in order to optimize shaping plasma-arc powder weld surfacing for the manufacture of forming tools suitable for high stresses. Schweissen und Schneiden/Welding and Cutting, 2002, 54(3), 165–169.
18.
DiltheyU.EllermeierJ.GladkijP.PavlenkoA. V.Combined plasma-arc powder surfacing. Schweissen und Schneiden/Welding and Cutting, May 1993, 45(5), E75–E76.
19.
DraugelatesU.BouaifiB.SchultzeS.Heavy-duty plasma-arc powder surfacing with duplex steels. Schweissen und Schneiden/Welding and Cutting, May 1999, 51(5), E77–E81.
20.
DraugelatesU.BouaifiB.GiesslerS.Two-powder plasma-arc surfacing of nickel-base alloys containing oxide ceramics. Schweissen und Schneiden/Welding and Cutting, November 1998, 50(11), 217–218.
21.
WangX.LiuH.Metal powder thermal behaviour during the plasma transferred-arc surfacing process. Surface and Coatings Technol., 4 August 1998, 106(2–3), 156–161.
