Basic Research On Accurate Forming Technology By The Hybrid Plasma Deposition And Milling

The Direct Rapid Manufacturing (DRM) of metal parts based on high energy density beam, including laser, electronic beam and plasma arc, is one of the most important developing aspects of rapid prototyping technology. Plasma Deposition Manufacturing (PDM) is one type of shape-creative and mass-creative parallelly rapid manufacturing technology using high energy density plasma beam as thermal resource. This technology has all features of general rapid prototyping and overcomes the existing shortcomings of rapid manufacturing method based on laser or electronic beam, such as high cost of equipment, low manufacturing speed, limited density of parts, and so on, which cause it to be one of the best methods for the short process rapid manufacturing technology with very low cost and near or even net shape, and it exhibits very important research value and wide extensive application prospect.As a new type of manufacturing technology based on layered manufacturing, Plasma Deposition rapid manufacturing in addition to have the stage effects which common to other rapid manufacturing technology, It also have the liquid metal flow in its own gravity and the effect of plasma arc and other unique phenomenon, These effects affect processing efficiency and parts precision severely. System-depth study of the main problem, the cause and the corresponding solutions of the plasma deposition manufacturing technology was carried out based on single-weld in this paper, The main contents include the following aspects:(1) The basic knowledge related to the plasma deposition manufacturing technology and manufacturing system were researched. And the plasma arc generated principles, forms and characteristics were analyzed, and the plasma deposition manufacturing principles and characteristics of the various subsystems were studied.(2) The major issues and factors of the plasma deposition Manufacturing Technology were analyzed in-depth, The affect degree of each technics parameter to the plasma deposition Manufacturing technology were educed by orthogonal experiment.(3) The effect mechanism of the deposition manufacturing process parameters, including transferred-arc current, scanning speed, stand-off point, deposition path, Working gas flow rate and powder feed rate, to deposition layer geometric characteristics were researched systematically, meanwhile, the corresponding improve measures were put forward.(4) Finally, The material properties and milling machining parameters of super alloy GH163 were analyzed, A metal parts with complex surface contour was manufactured by Hybrid Plasma Deposition and Milling in optimal parameter according to the technics experiment done before.This paper has provided prophase fundamental researches for the development of PDM technology on the base of theoretical foundation and craft experience. The research methods and experiment results also have some references for the deeper research for rapid deposition manufacturing.