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This paper reports on prediction of width and height of single-layer deposition by micro-plasma-transferred arc (μ-PTA) deposition process. It involved (i) 3D finite element simulation (3D-FES) of the melt pool using specific power of the micro-plasma, travel rate of worktable, deposition material feed rate, and temperature-dependent properties of the substrate material; (ii) calculation of its dimensions using image processing technique; and (iii) prediction of deposition width and height. The proposed approach was validated by comparing the predicted values with the corresponding experimental values for single-layer deposition of AISI P20 tool steel using different combinations of the μ-PTA deposition process parameters. Values of average errors as 6.11 and 7.15% for width and height of the single-layer deposition validates the simulation-predicted results. Study of influence of μ-PTA process parameters on deposition geometry revealed that micro-plasma power and travel rate of worktable significantly affect the width and height of the deposition layer. The proposed approach will be of great help in selecting the optimum values of deposition process parameters for any combination of substrate and deposition material thus improving accuracy and productivity of the additive layer manufactured parts.
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