In this study, a novel wire based plasma transferred arc (PTA)-laser hybrid additive manufacture process was proposed for deposition of large-scale titanium parts with high deposition rate and near-net shape. The optimum processing conditions, including the heat source configuration, wire feeding position, and arc-to-laser separation distance, were investigated. The benefits of using the hybrid process over the single PTA and laser deposition processes on their own were studied. The results show that compared to the single PTA process, the hybrid process has extended energy distribution and melt pool size, giving more interaction time of the wire with the heat sources and therefore a higher deposition rate. Compared to the laser process, the hybrid process has a much higher wire melting efficiency and tolerance to wire positioning accuracy. Owing to more distributed energy across the two heat sources, the likelihood of keyhole formation in the hybrid process is lower than that in the single PTA process. The best configuration for the hybrid process is the PTA leading, combined with front feeding of the wire. In this configuration, the PTA is used to melt the feedstock and the laser is used to control the melt pool size, which allows independent control of deposition rate and bead shape. A set of multi-layer walls was built to demonstrate the feasibility of this process for the manufacture of engineering parts. The results show that the achieved flat beads are very desirable for low surface waviness and lead to near-net-shape deposition. The main limitation of the hybrid process is remelting into the underlying layer. To overcome this, a multi-energy source process with more evenly distributed energy has been proposed.

在这项研究中，提出了一种新颖的基于线的等离子体转移电弧（PTA）-激光混合添加剂制造工艺，该工艺用于沉积具有高沉积速率和接近最终形状的大型钛零件。研究了最佳的加工条件，包括热源配置，送丝位置和电弧与激光的分离距离。研究了使用混合工艺胜过单个PTA和激光沉积工艺的好处。结果表明，与单一PTA工艺相比，混合工艺具有扩展的能量分布和熔池大小，从而使焊丝与热源的相互作用时间更长，因此沉积速率更高。与激光工艺相比，混合工艺具有更高的焊丝熔化效率和对焊丝定位精度的耐受性。由于在两个热源之间分配的能量更多，因此在混合过程中形成小孔的可能性比在单个PTA过程中要小。混合工艺的最佳配置是PTA引导，并结合焊丝的前馈。在这种配置中，PTA用于熔化原料，而激光用于控制熔池大小，从而可以独立控制沉积速率和珠粒形状。建造了一组多层墙以证明该工艺在制造工程零件中的可行性。结果表明，所获得的扁平珠粒对于低表面波纹度是非常合乎需要的并且导致近净形状的沉积。混合过程的主要局限性在于重熔到底层。为了克服这个问题