Numerical simulation and experimental characterization of a single-seam plasma wire arc additive manufacturing process for Ti-6Al-4V

Arc welding processes are increasingly being used in the additive manufacturing of metal components. Physics-based modeling of welding processes enables the study of welding parameter effects on the final weld shape, residual stress state, and distortion, helping to improve weld quality and reduce costs. However, the quality of the process simulation strongly depends on the mathematical description of the heat source. The parameters of the heat source model have a significant influence on the temperature field and, consequently, on the distortion and residual stress fields. This paper presents a trial-and-error method for determining the parameters for Goldak’s double-ellipsoidal heat source model. The transient temperature distribution and the size of the melt pool are determined through experimental studies. Numerical models are then set up in Simufact Welding 8.0 with a set of heat source parameters to reproduce the experimental trials. By comparing numerical finite element results with experimental results, the heat source parameters for a multi-pass additive manufacturing process are successfully calibrated and identified.