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<p>Plasma Transfer Arc Additive Manufacturing (PTA-AM) is a developing technology in printing additive manufacturing (AM) parts. There are numerous processing parameters in the PTA-AM system that need to be controlled and studied to optimize the printing process. Torch offset from substrate, center gas, powder gas, shield gas, nozzle angle relative to welding direction, current, powder flow rate and table speed are all parameters that need to be controlled, with several levels each. Doing a full factorial using all the processing parameters to identify the most influential parameters during the printing of 17-4PH stainless steel would be tedious and inefficient. Taguchi design of experiments (DOE) was selected as a more efficient method of experimenting and identifying the most influential parameters. A Taguchi L’18 DOE was used to build 18 walls to narrow the processing parameters down to the most influential ones, using two new dimensionless numbers and signal to noise ratio analysis on Minitab. The two new dimensionless numbers are proposed to asses the effect of different input parameters on the quality of the part being built; the numbers are heat ratio and length ratio. Heat ratio combines the influence of different parameters that introduce heat into the system, while length ratio encompasses the parameters that pertain to the part’s height. Using the dimensionless numbers and a Minitab analysis of the output results from the first DOE concluded that powder flow rate, current and table speed are the most influential parameters; which were then used for a second, smaller DOE. The second Taguchi L’9 DOE was to verify that the three selected parameters were sufficient to build complex shapes: cylinders and squares, with acceptable mechanical properties. Both sets of DOEs studied the build height, bead width, oxide layer, surface roughness and porosity of all the parts to compare results. Oxide layer showed consistent results for both DOEs. Cylinders and squares made in the second DOE showed comparable results to parts made with traditional manufacturing.</p>

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Effect of process parameters on plasma transferred arc additive manufactured 17-4PH using the Taguchi method

  • 期刊论文

  • 发表日期：

    2026年2月5日

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  • Sandy El Moghazi,
  • Jose Guadalupe Mercado Rojas,
  • Tonya Wolfe,
  • Ahmed Qureshi,
  • Hani Henein

摘要

Plasma Transfer Arc Additive Manufacturing (PTA-AM) is a developing technology in printing additive manufacturing (AM) parts. There are numerous processing parameters in the PTA-AM system that need to be controlled and studied to optimize the printing process. Torch offset from substrate, center gas, powder gas, shield gas, nozzle angle relative to welding direction, current, powder flow rate and table speed are all parameters that need to be controlled, with several levels each. Doing a full factorial using all the processing parameters to identify the most influential parameters during the printing of 17-4PH stainless steel would be tedious and inefficient. Taguchi design of experiments (DOE) was selected as a more efficient method of experimenting and identifying the most influential parameters. A Taguchi L’18 DOE was used to build 18 walls to narrow the processing parameters down to the most influential ones, using two new dimensionless numbers and signal to noise ratio analysis on Minitab. The two new dimensionless numbers are proposed to asses the effect of different input parameters on the quality of the part being built; the numbers are heat ratio and length ratio. Heat ratio combines the influence of different parameters that introduce heat into the system, while length ratio encompasses the parameters that pertain to the part’s height. Using the dimensionless numbers and a Minitab analysis of the output results from the first DOE concluded that powder flow rate, current and table speed are the most influential parameters; which were then used for a second, smaller DOE. The second Taguchi L’9 DOE was to verify that the three selected parameters were sufficient to build complex shapes: cylinders and squares, with acceptable mechanical properties. Both sets of DOEs studied the build height, bead width, oxide layer, surface roughness and porosity of all the parts to compare results. Oxide layer showed consistent results for both DOEs. Cylinders and squares made in the second DOE showed comparable results to parts made with traditional manufacturing.