Design of experiments approach in directed energy deposition-arc with metals: optimization in pressure tank production

Directed energy deposition-arc with metals (DED-ARC/M) is gaining popularity in aerospace applications due to its cost-reduction potential and shorter lead times. A notable example of expensive products manufactured traditionally is pressure tanks with oval shapes. These parts are roughly machined from bulk material and then reduced to their final thickness. By employing DED-ARC technology, material waste and CNC machining time can be minimized, leading to a significant reduction in overall part costs. This paper focuses on the design of experiments (DoE) for optimizing welding parameters to manufacture a pressure tank for aerospace applications using 17–4 PH stainless steel. To meet the high-quality and lightweight requirements of aerospace applications, it is crucial to set the welding parameters correctly. The presented DoE consists of three stages. Initially, a number of single beads with distinct parameters are deposited for a layer height of 2–3 mm. Through geometric macro inspection, most of the single-bead parameters are eliminated. Using the remaining parameter sets, flat walls are manufactured, and the specimens are taken from these walls to assess their mechanical properties. Finally, the parameter sets that yield the highest mechanical quality are employed in the additive manufacturing of the pressure tank for aerospace applications.