A 3D dynamic analysis of thermal behavior during single-pass multi-layer weld-based rapid prototyping

Weld-based rapid prototyping enables the capacity of forming 3D complex parts. In rapid prototyping there exists the particular thermal cycling, being repeatedly heated at the same place, which is the basic cause of complex thermal stress. In this paper experiments are carried out to investigate the thermal characters of single-pass ten-layer deposition. Meanwhile a 3D transient heat transfer numerical simulation with temperature-dependent material properties is conducted to investigate temperature field evolution, thermal cycling character, temperature gradient and the effects of depositing directions on the thermal process of single-pass ten-layer rapid prototyping. The calculated results match the experimental measurements well. The research results show that the heat diffusion condition of molten pool becomes worse as the depositing height increases. With other parameters being constant, the heat diffusion condition can be significantly improved by optimizing the depositing directions. The heat diffusion condition of component with the same depositing directions is better than reverse directions. (C) 2010 Elsevier B.V. All rights reserved.