A 3D print device using a cold metal transfer arc welding station to melt a metallic filler wire is developed to build aluminium part by optimising the process parameters. First tests achieved using standard pre-recorded process parameters allow to study the effect of the travel speed and the average welding power on the geometrical characteristics of mono-layer deposits and on walls built by layers superposition. Finally, a parametric study of the effect of each process parameter controlling the shape of the arc current or voltage and the filler wire feeding is carried out in order to try to improve the geometrical regularity of the deposits, and to better understand the effect of each parameter on the melting of the filler wire, its transfer on the support plate, and the geometry of the formed bead.

4043 aluminium deposits were elaborated using a 3D print device equipped with a Cold Metal Transfer welding source. Two sets of process parameters leading to different average powers were compared in order to establish the relations between the powers and energies produced and the geometrical characteristics of the deposits. The effects of the travel speed and layer superposition on the transfer mechanisms as well as on the geometrical characteristics of the deposits were discussed for both sets of parameters. Finally, the formed microstructures were analysed and the porosity defects were quantified and discussed with regard to the heat input characteristics and the solidification conditions.

The flow through geometrically complex structures is an important engineering problem. In this work, the laminar flow through Triply Periodic Minimal Surface (TPMS) structures is numerically analyzed using Computational Fluid Dynamics (CFD) simulations. Two different TPMS structures were designed, and their porosity was characterized as a function of the isovalue. Then, CFD simulations were implemented to compute the pressure drop by systematically varying the flow velocity and the porosity of the structure. A Darcy–Forchheimer model was fitted to CFD results to calculate the inertial and permeability coefficients as functions of the porosity. These types of results can be very useful for designing fluid flow applications and devices (for instance, heat exchangers), as well as for integrating these TPMS structures since the flow can be very well estimated when using the porous medium model.

Monolayers of Ti and TiN coatings, as well as a Ti/TiN bilayer coating, were deposited on AISI M2 steel substrates using the PVD cathodic arc technique. The coatings had a thickness close to 5 μm and an average roughness between 98.6 and 110.1 μm due to the presence of microdroplets on the surface. The crystalline structure of the materials was analyzed using Grazing Incidence X-ray Diffraction (GIXRD) with an increase in temperature to study the dynamics of oxide formation. A phase composition study was conducted using the Rietveld refinement method. At the temperatures where critical growth of titanium oxides, both anatase and rutile, was observed, pin-on-disk tests were performed to study the tribological properties of the materials at high temperatures. It was determined that the oxidation temperature of Ti is around 450 °C, promoting the formation of a combination of anatase and rutile. However, the formation of rutile inhibits the formation of anatase, which is stable above 600 °C. In contrast, TiN showed an oxidation temperature of 550 °C, with an exclusive growth of the rutile phase. The Ti/TiN bilayer exhibited mixed behavior, with the initial growth of anatase promoted by Ti, followed by the formation of rutile. Oxidation and tribo-oxidation dominated the wear behavior of the surfaces, showing a transition from mechanisms related to abrasion at low and medium temperatures to a combination of abrasion and adhesion mechanisms at high temperatures (800 °C).