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Text: Thomas Masuch
Developed specifically to meet the requirements of titanium processing, the ArcTitan combines a fully enclosed inert gas atmosphere with a plasma-based WAAM process. The aim is to achieve “a level of process control for the additive manufacturing of titanium that has not previously been possible.”
Titanium’s high strength-to-weight ratio, excellent corrosion resistance and outstanding performance under demanding operating conditions make it one of the most attractive engineering materials for industrial applications. However, its sensitivity to contamination during processing places stringent demands on the manufacturing process.
The core of the ArcTitan is an enclosed build chamber. The entire process chamber is flooded with inert gas to maintain a uniform atmosphere throughout the build process. According to GEFERTEC, this eliminates the need for additional enclosures or external shielding gas systems and provides stable process conditions that support reliable and consistent manufacturing. “The greatest challenge in the Additive Manufacturing of titanium is ensuring reproducible process conditions,” says Johannes Zuckschwerdt, Managing Director of the Berlin-based company.
The system design is complemented by a plasma-based welding process with a focused and highly stable arc that allows precise control of heat input and ensures consistent part quality. Combined with the enclosed build chamber, this creates a manufacturing system in which process conditions can be tightly controlled throughout the entire build.
According to Gefertec, every relevant system component – from gas management and sensor technology to wire feeding and process parameter control – has been tailored to the specific requirements of titanium. The machine holds oxygen levels inside the build chamber at between 10 and 15 parts per million and achieves deposition rates of up to 3 kg per hour inside the 2,000 × 700 × 1,000 mm build envelope. Gefertec also offers custom systems, whose size and equipment are configured to customer requirements.
The combination of a fully inert process environment and a plasma-based WAAM process is particularly suitable for applications that demand high levels of material quality and process reliability. These include components for the aerospace industry, the energy sector and other high-performance industrial applications.
