Innovative Process Model of Ti-6Al-4V Additive Layer Manufacturing Using Cold Metal Transfer (CMT)

Abstract

New approaches to modern manufacture have emerged from Additive Layer Manufacturing (ALM) technologies over the last 25 years. These approaches provide form, fit and function to a wide range of metallic alloys and components. Wire + Arc Additive Layer Manufacture (WAALM) has gained the interest of the research community in recent years due to its high deposition rate and efficiency (100%). The technique has been presented to the aerospace manufacturing industry as a unique low cost solution for large structural components manufacture. With this process product development time, capital investment and “Buy-to-Fly” ratios can be significantly improved. One of the greatest challenges of WAALM systems is the control algorithms needed to predict optimum welding parameters in order to achieve a specific target wall width/height requirement, and maximum deposition efficiency. This paper describes a process model for multilayer Ti-6Al-4V deposition using the Gas Metal Arc Welding based process of Cold Metal Transfer. The process model is based on a Systematic Experimental Approach carried out using a regression analysis. The mathematical relationships obtained are ready to use in future large scale “intelligent” WAALM controllers.