Process Mapping of Transient Melt Pool Response in Wire Feed E-Beam Additive Manufacturing of Ti-6Al-4V

Wire feed electron beam additive manufacturing processes are candidates for manufacturing and repair in the aerospace industry. In order to implement feedback or feedforward control approaches, the time needed for a change in process variables to translate into changes in melt pool dimensions is a critical concern. In this research, results from 3D finite element simulations of deposition of Ti-6Al-4V are presented quantifying the transient response of melt pool dimensions to rapid changes in beam power and travel velocity. Results are plotted in beam power vs. beam velocity space, following work by the authors developing P-V Process Maps for steady-state melt pool geometry. Transient responses are determined over a wide range of process variables. Simulation results are compared to initial results from experiments performed at NASA Langley Research Center.Mechanical Engineerin