Coaxial laser directed energy deposition with wire of thin-walled duplex stainless steel parts: Process discontinuities and their impact on the mechanical properties

Odermatt, Anton; Dorn, Falk; Ventzke, Volker; Kashaev, Nikolai

doi:10.1016/j.cirpj.2022.02.019

Cited by 11 publications

(7 citation statements)

References 20 publications

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“…Maintaining a nominal focal distance while keeping other parameters constant ensures a stable process. A high offset position causes the beam to focus on the wire, while a low offset leads to insufficient melting of the wire [95,96]. Experiments on the effect of focal position on process stability reveal that at a low focal position, the laser beam is too large on the substrate, acting as a beam with low intensity.…”

Section: Focal Distancementioning

confidence: 99%

“…Relatively low laser power in correlation with high WFS, TS, and low focal offset can both lead to stubbing. Stubbing can be avoided by carefully increasing the laser power, decreasing WFS as well as adjusting the focal offset [95]. Figure 20b-d Dripping occurs with high laser power, inadequate focal offset (i.e., high offset), or a combination of insufficient WFS and TS.…”

Section: External Defectsmentioning

confidence: 99%

“…Figure 20b-d Dripping occurs with high laser power, inadequate focal offset (i.e., high offset), or a combination of insufficient WFS and TS. To address this issue, the WFS and TS can be increased to an optimal value until there is sufficient material deposited and a smooth deposition is achieved [57,84,95,128,150,159,160].…”

Section: External Defectsmentioning

confidence: 99%

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A Review on Wire-Laser Directed Energy Deposition: Parameter Control, Process Stability, and Future Research Paths

Ghanadi,

Pasebani

2024

JMMP

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Wire-laser directed energy deposition has emerged as a transformative technology in metal additive manufacturing, offering high material deposition efficiency and promoting a cleaner process environment compared to powder processes. This technique has gained attention across diverse industries due to its ability to expedite production and facilitate the repair or replication of valuable components. This work reviews the state-of-the-art in wire-laser directed energy deposition to gain a clear understanding of key process variables and identify challenges affecting process stability. Furthermore, this paper explores modeling and monitoring methods utilized in the literature to enhance the final quality of fabricated parts, thereby minimizing the need for repeated experiments, and reducing material waste. By reviewing existing literature, this paper contributes to advancing the current understanding of wire-laser directed energy deposition technology. It highlights the gaps in the literature while underscoring research needs in wire-laser directed energy deposition.

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Section: Focal Distancementioning

confidence: 99%

Section: External Defectsmentioning

confidence: 99%

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A Review on Wire-Laser Directed Energy Deposition: Parameter Control, Process Stability, and Future Research Paths

Ghanadi,

Pasebani

2024

JMMP

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“…Wire-feed Laser Additive Manufacturing (WLAM) is an economical additive manufacturing method for complex geometries, good surface quality and near net shapes [3]. In IOP Publishing doi:10.1088/1757-899X/1296/1/012005 2 comparison to the AM methods using electric arc to melt and deposit the material, in WLAM processes energy coming from the laser can be more focused which results in smaller melt pools, smaller feature size, and more efficient energy consumption [4]. These characteristics of WLAM result in the final product with more controlled residual stresses and phase transformations [5].…”

Section: Introductionmentioning

confidence: 99%

Using artificial neural networks to model single bead geometries processed by laser-wire direct energy deposition

Asadi,

Queguineur,

Ylä-Autio

et al. 2023

IOP Conf. Ser.: Mater. Sci. Eng.

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Wire-feed laser additive manufacturing processes have gained researchers’ attention because of their potential to reduce material waste, guarantee accuracy, increase material quality and density, and produce a wide dimensional range of final products. Nevertheless, printing materials with desired geometrical properties of the beads is still challenging in such processes. This might be attributed to the need for more sufficient experimental data and precise modeling approaches. In this study, an architecture based on Artificial Neural Networks (ANNs) is developed to model the bead geometries (width, height, and area), considering the wire feed rate, laser power, and travel speed as process parameters. A design-of-experiment based on full factorial design is considered for processing single beads with a Fraunhofer coaxial wire-feed laser system. Inconel 625 wire with a diameter of 1.14 mm and stainless steel substrate are utilized as the experimental materials. Geometrical data is obtained using a laser scanner model RA-7525 SE with 0.026mm volumetric accuracy. The beads’ geometrical details are provided as the feeding data for the proposed ANN. For each bead, a length of 10 mm is considered to calculate the average geometrical parameters, which increases the accuracy of the dataset in comparison to the values acquired via a macroscopic picture of the cross-section of each weld bead. A variety of hyperparameters are chosen and compared regarding precision criteria, including Mean Square Error (MSE), to increase the model‘s accuracy. A train-test separation strategy is considered to evaluate the model‘s accuracy on independent data points. The outcome of this research is an ANN-based geometry prediction model that can be utilized to enhance the development of offline path planners and optimize process parameter selection for a precise geometry toward process control.

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“…Among many AM techniques for processing metal alloys, one can distinguish two widely used groups of technologies: direct energy deposition (DED) and powder bed fusion (PBF) [9,10]. Comparing the DED technique with PBF, it can be claimed that DED is characterized by a lower dimensional and shape accuracy but higher material deposition efficiency [11]. Although PBF usually permits obtaining better component properties, in some cases, DED allows achieving better mechanical properties and easier gradation by varying material composition [12].…”

Section: Introductionmentioning

confidence: 99%

Processability of High-Speed Steel by Coaxial Laser Wire Deposition Technology for Additive Remanufacturing of Cutting Tool

Koruba,

Kędzia,

Dziedzic

et al. 2023

Applied Sciences

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The recently introduced Coaxial Laser Wire Deposition technology can become a new promising method for remanufacturing high-complexity and expensive cutting tools (e.g., flat broach), which will have a significant impact on their service life. In addition, it is an innovative approach to tool management. An analysis of the feasibility of processing cobalt-added HSS powder steels was carried out for single clads and multilayer structures. The effect of process parameters (laser, beam power, travel speed, wire feed rate) on geometric properties, hardness and microstructure was discussed. In order to avoid cracking during multilayer deposition, an additional preheating to 320 °C was applied. Two sets of process parameters with high and low heat input were obtained. Both sets lead to crack-free structures that fulfill geometric (≥2.5 mm in height) and hardness (≥700 HV) requirements.

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Coaxial laser directed energy deposition with wire of thin-walled duplex stainless steel parts: Process discontinuities and their impact on the mechanical properties

Cited by 11 publications

References 20 publications

A Review on Wire-Laser Directed Energy Deposition: Parameter Control, Process Stability, and Future Research Paths

A Review on Wire-Laser Directed Energy Deposition: Parameter Control, Process Stability, and Future Research Paths

Using artificial neural networks to model single bead geometries processed by laser-wire direct energy deposition

Processability of High-Speed Steel by Coaxial Laser Wire Deposition Technology for Additive Remanufacturing of Cutting Tool

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