Micro-plasma transferred arc (μ-PTA) wire deposition is a cost effective additive layer manufactu... more Micro-plasma transferred arc (μ-PTA) wire deposition is a cost effective additive layer manufacturing (ALM) process used for remanufacturing/ repair of high value components. Prediction of geometry and cross-sectional area of each deposition track and deposition overlap between the successive deposition tracks helps in optimizing the deposition strategies and automated repair and remanufacturing of the components by μ-PTA process. This paper presents investigations on enhancing the deposition quality in μ-PTA process by approximating deposition geometry as an elliptical arc with an objective to predict its cross-sectional area and to optimize the deposition overlap between the successive deposition tracks. The model was validated using the experimental apparatus developed for the μ-PTA wire deposition process. The predictions were compared with the previously developed models of deposition geometry considering it as an arc of parabola, circle and cosine function. The results proved ...
Plasma metal deposition (PMD) is an additive manufacturing process capable of layer by layer cons... more Plasma metal deposition (PMD) is an additive manufacturing process capable of layer by layer construction , repair, and reconstruction of metallic parts. One of the important characteristics of cladding with PMD is the ability to control the wire feed, plasma arc energy, thus allowing the melt pool to be controlled. In this paper stainless steel 316L was deposited in the form of wire on a block of mild steel. Experiments were focused to infer the influence of plasma power, travel speed and wire feed rate on the quality of track. Different parameters were varied to observe the various geometrical parameters and their relationship with the energy source and material feed rate was established. The results show that plasma power and wire feed rate have a significant impact on height and width of the deposited track. Aspect ratios ranging from 0.85 to 4.6 were obtained. Higher values of aspect ratio at lower wire feed rates and at optimum plasma power was further used for deposition of d...
ABSTRACT Micro-plasma transferred arc (μ-PTA) wire deposition is a cost effective additive layer ... more ABSTRACT Micro-plasma transferred arc (μ-PTA) wire deposition is a cost effective additive layer manufacturing (ALM) process used for remanufacturing/ repair of high value components. Prediction of geometry and cross-sectional area of each deposition track and deposition overlap between the successive deposition tracks helps in optimizing the deposition strategies and automated repair and remanufacturing of the components by μ-PTA process. This paper presents investigations on enhancing the deposition quality in μ-PTA process by approximating deposition geometry as an elliptical arc with an objective to predict its cross-sectional area and to optimize the deposition overlap between the successive deposition tracks. The model was validated using the experimental apparatus developed for the μ-PTA wire deposition process. The predictions were compared with the previously developed models of deposition geometry considering it as an arc of parabola, circle and cosine function. The results proved the superiority of the elliptical function based model over the previous models for predicting cross-sectional area and overlap of the deposition track for μ-PTA wire deposition process. The deposition overlap was optimized to predict the center distance between successive deposition tracks to maximize the quality of deposit over a flat surface.
The peculiar feature of friction materials to absorb the kinetic energy of rotating wheels of an ... more The peculiar feature of friction materials to absorb the kinetic energy of rotating wheels of an automobile to control the speed makes them remarkable in automobile field. The regulation of speed cannot be achieved with the use of single phase material as a friction material. Consequently, the friction material should be comprised of composite materials which consist of several ingredients. Incidentally, the friction materials were formulated with friction modifier, binders, fillers and reinforcements. Due to its pleasant physical properties, asbestos was being used as a filler. Past few decades, it is found that asbestos causes dangerous cancer to its inhaler, which provides a scope its replacement. Several attempts have been made to find an alternative to the hazardous asbestos. The efforts made by different researchers for the impact of every composition of composite friction material in the field are reviewed and studied for their effect on the properties of friction material. S...
Micro-plasma transferred arc (µPTA) additive manufacturing is one of the newest options for reman... more Micro-plasma transferred arc (µPTA) additive manufacturing is one of the newest options for remanufacturing of dies and molds surfaces in near-millimeter range leading to extended usage of the same. We deployed an automatic micro-plasma deposition setup to deposit a wire of 300 µm of AISI P20 tool steel on the substrate of same material for the potential application in remanufacturing of die and mold surface. Our present research effort is to establish µPTA additive manufacturing as a viable economical and cleaner methodology for potential industrial applications. We undertook the optimization of single weld bead geometry as the first step in our present study. Bead-on-plate trials were conducted to deposit single bead geometry at various processing parameters. The bead geometry (shape and size) and dilution were measured and parametric dependence was derived. A set of parameters leading to reproducible regular and smooth single bead geometry were identified and used to prepare a thin wall for mechanical testing. The deposits were subjected to material characterization such as microscopic studies, micro-hardness measurements and tensile test. The process was compared qualitatively with other deposition processes involving high energy density beams and was found to be advantageous in terms of low initial and running cost with comparable properties. The outcome of the study confirmed the process capability of µPTA deposition leading to deployment of costeffective and environmentally friendlier technology for die and mold remanufacturing.
Micro-plasma transferred arc (u-PTA) deposition process is a recently developed material and ene... more Micro-plasma transferred arc (u-PTA) deposition process is a recently developed material and energy efficient additive layer manufacturing process for metallic deposition which is capable of bridging the gap between capabilities of high energy based and conventional arc-based deposition processes. Development
of model of deposition geometry is essential to study the relationship and influence of various process parameters
on the deposition geometry parameters. This paper reports development of a thermal model to predict single track deposition width and height in terms of three important process parameters of u-PTA deposition process (i.e. input power, volumetric deposition rate and travel speed of worktable) using fundamental principles of energy balance and heat transfer. The developed model was validated by comparing the model predicted results with the experimental results of single track deposition geometries corresponding to various parametric combinations in the -PTA deposition process. The predicted values were found in very good agreement with the experimental results thus validating the developed models. The developed model has wide applicability because it depends only on thermal properties of the substrate and deposition materials and is independent of form of the deposition material therefore it can be used for predicting deposition geometry for any combination of substrate and deposition materials and for any form of the deposition material.
Micro-plasma transferred arc (µ-PTA) deposition process is a recently developed material and ener... more Micro-plasma transferred arc (µ-PTA) deposition process is a recently developed material and energy efficient additive layer manufacturing process for metallic deposition which is capable of bridging the gap between capabilities of high energy based and conventional arc-based deposition processes. Development of model of deposition geometry is essential to study the relationship and influence of various process parameters on the deposition geometry parameters. This paper reports development of a thermal model to predict single track deposition width and height in terms of three important process parameters of µ-PTA deposition process (i.e. input power, volumetric deposition rate and travel speed of worktable) using fundamental principles of energy balance and heat transfer. The developed model was validated by comparing the model predicted results with the experimental results of single track deposition geometries corresponding to various parametric combinations in the µ-PTA deposition process. The predicted values were found in very good agreement with the experimental results thus validating the developed models. The developed model has wide applicability because it depends only on thermal properties of the substrate and deposition materials and is independent of form of the deposition material therefore it can be used for predicting deposition geometry for any combination of substrate and deposition materials and for any form of the deposition material.
Micro-plasma transferred arc (μ-PTA) wire deposition is a cost effective additive layer manufactu... more Micro-plasma transferred arc (μ-PTA) wire deposition is a cost effective additive layer manufacturing (ALM) process used for remanufacturing/ repair of high value components. Prediction of geometry and cross-sectional area of each deposition track and deposition overlap between the successive deposition tracks helps in optimizing the deposition strategies and automated repair and remanufacturing of the components by μ-PTA process. This paper presents investigations on enhancing the deposition quality in μ-PTA process by approximating deposition geometry as an elliptical arc with an objective to predict its cross-sectional area and to optimize the deposition overlap between the successive deposition tracks. The model was validated using the experimental apparatus developed for the μ-PTA wire deposition process. The predictions were compared with the previously developed models of deposition geometry considering it as an arc of parabola, circle and cosine function. The results proved ...
Plasma metal deposition (PMD) is an additive manufacturing process capable of layer by layer cons... more Plasma metal deposition (PMD) is an additive manufacturing process capable of layer by layer construction , repair, and reconstruction of metallic parts. One of the important characteristics of cladding with PMD is the ability to control the wire feed, plasma arc energy, thus allowing the melt pool to be controlled. In this paper stainless steel 316L was deposited in the form of wire on a block of mild steel. Experiments were focused to infer the influence of plasma power, travel speed and wire feed rate on the quality of track. Different parameters were varied to observe the various geometrical parameters and their relationship with the energy source and material feed rate was established. The results show that plasma power and wire feed rate have a significant impact on height and width of the deposited track. Aspect ratios ranging from 0.85 to 4.6 were obtained. Higher values of aspect ratio at lower wire feed rates and at optimum plasma power was further used for deposition of d...
ABSTRACT Micro-plasma transferred arc (μ-PTA) wire deposition is a cost effective additive layer ... more ABSTRACT Micro-plasma transferred arc (μ-PTA) wire deposition is a cost effective additive layer manufacturing (ALM) process used for remanufacturing/ repair of high value components. Prediction of geometry and cross-sectional area of each deposition track and deposition overlap between the successive deposition tracks helps in optimizing the deposition strategies and automated repair and remanufacturing of the components by μ-PTA process. This paper presents investigations on enhancing the deposition quality in μ-PTA process by approximating deposition geometry as an elliptical arc with an objective to predict its cross-sectional area and to optimize the deposition overlap between the successive deposition tracks. The model was validated using the experimental apparatus developed for the μ-PTA wire deposition process. The predictions were compared with the previously developed models of deposition geometry considering it as an arc of parabola, circle and cosine function. The results proved the superiority of the elliptical function based model over the previous models for predicting cross-sectional area and overlap of the deposition track for μ-PTA wire deposition process. The deposition overlap was optimized to predict the center distance between successive deposition tracks to maximize the quality of deposit over a flat surface.
The peculiar feature of friction materials to absorb the kinetic energy of rotating wheels of an ... more The peculiar feature of friction materials to absorb the kinetic energy of rotating wheels of an automobile to control the speed makes them remarkable in automobile field. The regulation of speed cannot be achieved with the use of single phase material as a friction material. Consequently, the friction material should be comprised of composite materials which consist of several ingredients. Incidentally, the friction materials were formulated with friction modifier, binders, fillers and reinforcements. Due to its pleasant physical properties, asbestos was being used as a filler. Past few decades, it is found that asbestos causes dangerous cancer to its inhaler, which provides a scope its replacement. Several attempts have been made to find an alternative to the hazardous asbestos. The efforts made by different researchers for the impact of every composition of composite friction material in the field are reviewed and studied for their effect on the properties of friction material. S...
Micro-plasma transferred arc (µPTA) additive manufacturing is one of the newest options for reman... more Micro-plasma transferred arc (µPTA) additive manufacturing is one of the newest options for remanufacturing of dies and molds surfaces in near-millimeter range leading to extended usage of the same. We deployed an automatic micro-plasma deposition setup to deposit a wire of 300 µm of AISI P20 tool steel on the substrate of same material for the potential application in remanufacturing of die and mold surface. Our present research effort is to establish µPTA additive manufacturing as a viable economical and cleaner methodology for potential industrial applications. We undertook the optimization of single weld bead geometry as the first step in our present study. Bead-on-plate trials were conducted to deposit single bead geometry at various processing parameters. The bead geometry (shape and size) and dilution were measured and parametric dependence was derived. A set of parameters leading to reproducible regular and smooth single bead geometry were identified and used to prepare a thin wall for mechanical testing. The deposits were subjected to material characterization such as microscopic studies, micro-hardness measurements and tensile test. The process was compared qualitatively with other deposition processes involving high energy density beams and was found to be advantageous in terms of low initial and running cost with comparable properties. The outcome of the study confirmed the process capability of µPTA deposition leading to deployment of costeffective and environmentally friendlier technology for die and mold remanufacturing.
Micro-plasma transferred arc (u-PTA) deposition process is a recently developed material and ene... more Micro-plasma transferred arc (u-PTA) deposition process is a recently developed material and energy efficient additive layer manufacturing process for metallic deposition which is capable of bridging the gap between capabilities of high energy based and conventional arc-based deposition processes. Development
of model of deposition geometry is essential to study the relationship and influence of various process parameters
on the deposition geometry parameters. This paper reports development of a thermal model to predict single track deposition width and height in terms of three important process parameters of u-PTA deposition process (i.e. input power, volumetric deposition rate and travel speed of worktable) using fundamental principles of energy balance and heat transfer. The developed model was validated by comparing the model predicted results with the experimental results of single track deposition geometries corresponding to various parametric combinations in the -PTA deposition process. The predicted values were found in very good agreement with the experimental results thus validating the developed models. The developed model has wide applicability because it depends only on thermal properties of the substrate and deposition materials and is independent of form of the deposition material therefore it can be used for predicting deposition geometry for any combination of substrate and deposition materials and for any form of the deposition material.
Micro-plasma transferred arc (µ-PTA) deposition process is a recently developed material and ener... more Micro-plasma transferred arc (µ-PTA) deposition process is a recently developed material and energy efficient additive layer manufacturing process for metallic deposition which is capable of bridging the gap between capabilities of high energy based and conventional arc-based deposition processes. Development of model of deposition geometry is essential to study the relationship and influence of various process parameters on the deposition geometry parameters. This paper reports development of a thermal model to predict single track deposition width and height in terms of three important process parameters of µ-PTA deposition process (i.e. input power, volumetric deposition rate and travel speed of worktable) using fundamental principles of energy balance and heat transfer. The developed model was validated by comparing the model predicted results with the experimental results of single track deposition geometries corresponding to various parametric combinations in the µ-PTA deposition process. The predicted values were found in very good agreement with the experimental results thus validating the developed models. The developed model has wide applicability because it depends only on thermal properties of the substrate and deposition materials and is independent of form of the deposition material therefore it can be used for predicting deposition geometry for any combination of substrate and deposition materials and for any form of the deposition material.
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Papers by Suyog Jhavar
additive manufacturing as a viable economical and cleaner methodology for potential industrial
applications. We undertook the optimization of single weld bead geometry as the first step in our
present study. Bead-on-plate trials were conducted to deposit single bead geometry at various
processing parameters. The bead geometry (shape and size) and dilution were measured and parametric dependence was derived. A set of parameters leading to reproducible regular and smooth single bead geometry were identified and used to prepare a thin wall for mechanical testing. The deposits were subjected to material characterization such as microscopic studies, micro-hardness measurements and tensile test. The process was compared qualitatively with
other deposition processes involving high energy density beams and was found to be
advantageous in terms of low initial and running cost with comparable properties. The outcome
of the study confirmed the process capability of µPTA deposition leading to deployment of costeffective
and
environmentally friendlier technology for die and mold remanufacturing.
of model of deposition geometry is essential to study the relationship and influence of various
process
parameters
on
the deposition geometry parameters. This paper reports development of a thermal model to predict single track deposition width and height in terms of three important process parameters of u-PTA deposition process (i.e. input power, volumetric deposition rate and travel speed of worktable) using fundamental principles of energy balance and heat transfer. The developed model was validated by comparing the model predicted results with the experimental results of single track deposition geometries corresponding to various parametric combinations in the -PTA deposition process. The predicted values were found in very good agreement with the experimental results thus validating the developed models. The developed model has wide applicability because it depends only on thermal properties of the substrate
and deposition materials and is independent of form of the deposition material therefore it can be used for predicting deposition geometry for any combination of substrate and deposition materials and for any form of the deposition material.
additive manufacturing as a viable economical and cleaner methodology for potential industrial
applications. We undertook the optimization of single weld bead geometry as the first step in our
present study. Bead-on-plate trials were conducted to deposit single bead geometry at various
processing parameters. The bead geometry (shape and size) and dilution were measured and parametric dependence was derived. A set of parameters leading to reproducible regular and smooth single bead geometry were identified and used to prepare a thin wall for mechanical testing. The deposits were subjected to material characterization such as microscopic studies, micro-hardness measurements and tensile test. The process was compared qualitatively with
other deposition processes involving high energy density beams and was found to be
advantageous in terms of low initial and running cost with comparable properties. The outcome
of the study confirmed the process capability of µPTA deposition leading to deployment of costeffective
and
environmentally friendlier technology for die and mold remanufacturing.
of model of deposition geometry is essential to study the relationship and influence of various
process
parameters
on
the deposition geometry parameters. This paper reports development of a thermal model to predict single track deposition width and height in terms of three important process parameters of u-PTA deposition process (i.e. input power, volumetric deposition rate and travel speed of worktable) using fundamental principles of energy balance and heat transfer. The developed model was validated by comparing the model predicted results with the experimental results of single track deposition geometries corresponding to various parametric combinations in the -PTA deposition process. The predicted values were found in very good agreement with the experimental results thus validating the developed models. The developed model has wide applicability because it depends only on thermal properties of the substrate
and deposition materials and is independent of form of the deposition material therefore it can be used for predicting deposition geometry for any combination of substrate and deposition materials and for any form of the deposition material.