Directed Energy Deposition Processes

Gibson, Ian; Rosen, David W.; Stucker, Brent

doi:10.1007/978-1-4939-2113-3_10

Cited by 157 publications

(130 citation statements)

References 6 publications

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“…Currently, powder bed platforms are well suited for low-volume manufacturing of small replacement parts with medium-to high-complexity geometry and a procedure for Ti6Al4V using EB melting has been reported in [7]. By contrast, DED technologies have evolved from welding based platforms, traditionally designed for joining, cladding, coating, and repair [8][9][10][11], that have been integrated with computer-aided design software and, increasingly, also with in-line vision and metrology inspection systems. ese AM processes have evolved rapidly and matured sufficiently to deliberate retrofits and repairs for a broad range of structural metal alloys and functional applications.…”

Section: Introductionmentioning

confidence: 99%

Titanium Alloy Repair with Wire-Feed Electron Beam Additive Manufacturing Technology

Wanjara

Watanabe

Formanoir

et al. 2019

Advances in Materials Science and Engineering

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Wire feeding can be combined with different heat sources, for example, arc, laser, and electron beam, to enable additive manufacturing and repair of metallic materials. In the case of titanium alloys, the vacuum operational environment of electron beam systems prevents atmospheric contamination during high-temperature processing and ensures high performance and reliability of additively manufactured or repaired components. In the present work, the feasibility of developing a repair process that emulates refurbishing an “extensively eroded” fan blade leading edge using wire-feed electron beam additive manufacturing technology was examined. The integrity of the Ti6Al4V wall structure deposited on a 3 mm thick Ti6Al4V substrate was verified using X-ray microcomputed tomography with a three-dimensional reconstruction. To understand the geometrical distortion in the substrate, three-dimensional displacement mapping with digital image correlation was undertaken after refurbishment and postdeposition stress relief heat treatment. Other characteristics of the repair were examined by assessing the macro- and microstructure, residual stresses, microhardness, tensile and fatigue properties, and static and dynamic failure mechanisms.

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Section: Introductionmentioning

confidence: 99%

Titanium Alloy Repair with Wire-Feed Electron Beam Additive Manufacturing Technology

Wanjara

Watanabe

Formanoir

et al. 2019

Advances in Materials Science and Engineering

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“…The capability to produce fully dense, as well as gradient objects, makes the DED more attractive, concerning the powder bed systems, in the manufacturing of large and/or functionally graded components. Despite the advantages of deposition by wire, such as full materials efficiency, its requirement regarding the difficulties in delivering the wire through complex geometries and the higher surface roughness limits its applications in different fields [34][35][36]. For these reasons, the powder is preferred, and it is the most common and popular form of material used in the DED process.…”

Section: Directed Energy Deposition (Ded)mentioning

confidence: 99%

“…Selection of a low energy density results in limited melting of provided material, while very high energy density leads to excessive melting of the substrate, undesirable dilution of deposition, and evaporation of some alloying elements from the melt pool. A sufficient beam interaction time should also be employed for deposition to provide enough time for mixing and homogenizing the deposition, and for fast cooling of the melt pool to Despite the advantages of deposition by wire, such as full materials efficiency, its requirement regarding the difficulties in delivering the wire through complex geometries and the higher surface roughness limits its applications in different fields [34][35][36]. For these reasons, the powder is preferred, and it is the most common and popular form of material used in the DED process.…”

Section: Directed Energy Deposition (Ded)mentioning

confidence: 99%

Application of Directed Energy Deposition-Based Additive Manufacturing in Repair

et al. 2019

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In the circular economy, products, components, and materials are aimed to be kept at the utility and value all the lifetime. For this purpose, repair and remanufacturing are highly considered as proper techniques to return the value of the product during its life. Directed Energy Deposition (DED) is a very flexible type of additive manufacturing (AM), and among the AM techniques, it is most suitable for repairing and remanufacturing automotive and aerospace components. Its application allows damaged component to be repaired, and material lost in service to be replaced to restore the part to its original shape. In the past, tungsten inert gas welding was used as the main repair method. However, its heat affected zone is larger, and the quality is inferior. In comparison with the conventional welding processes, repair via DED has more advantages, including lower heat input, warpage and distortion, higher cooling rate, lower dilution rate, excellent metallurgical bonding between the deposited layers, high precision, and suitability for full automation. Hence, the proposed repairing method based on DED appears to be a capable method of repairing. Therefore, the focus of this study was to present an overview of the DED process and its role in the repairing of metallic components. The outcomes of this study confirm the significant capability of DED process as a repair and remanufacturing technology.

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“…DED of ceramics is difficult as it requires the feedstock to be heated to form a molten pool to fuse into the previous layer, which is a challenging physical process for many ceramics. In addition, DED requires a slow deposition rate increasing the build time of the process [17]. Finally, even though ceramic paste extrusion is inexpensive, it limits the resolution of the extrusion and the ability to manufacture complex geometric shapes due to rheological properties of the paste [18].…”

Section: Introductionmentioning

confidence: 99%

Polymer-derived SiOC replica of material extrusion-based 3-D printed plastics

Kulkarni

Sorarù

Pearce

2020

Additive Manufacturing

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A promising method for obtaining ceramic components with additive manufacturing (AM) is to use a two-step process of first printing the artifact in polymer and then converting it to ceramic using pyrolysis to form polymer derived ceramics (PDCs). AM of ceramic components using PDCs has been demonstrated with a number of high-cost techniques, but data is lacking for fused filament fabrication (FFF)-based 3-D printing. This study investigates the potential to use the lower-cost, more widespread and accessible FFF-based 3-D printing of PDCs. Low-cost FFF machines have a resolution limit set by the nozzle width, which is inferior to the resolutions obtained with expensive SLA or SLS AM systems. To match the performance a partial PDC conversion is used here, where only the outer surface of the printed polymer frame is converted to ceramic. Here the FFF-based 3-D printed sample is coated with a preceramic polymer and then it is converted into the corresponding PDC sample with a high temperature pyrolysis process. A screening experiment is performed on commercial filaments to obtain ceramic 3-D prints by surface coating both hard thermoplastics: poly lactic acid (PLA), polycarbonate (PC), nylon alloys, polypropylene (PP), polyethylene terephthalate glycol (PETG), polyethylene terephthalate (PET), and co-polyesters; and flexible materials including: flexible PLA, thermoplastic elastomer and thermoplastic polyurethane filaments. Mass and volume changes were quantified for the soaking and pyrolysis steps to form a hollow ceramic skin. All 3-D printing materials extruded at 250 microns successfully produced ceramics skins of less than 100 microns. Details on the advantages and disadvantages of the different 3-D printing polymer precursors are discussed for this processing regime. The results are analyzed and discussed in order to provide guidance for more widespread application of AM of PDCs. Graphical Abstract Highlights• Additive manufacturing of polymer derived ceramics with fused filament fabrication • Producing ceramics with hollow struts by surface coating with preceramic polymers • Creating a multi-level porous system with stable geometry • All 3-D printing materials produced ceramics skins of less than 100 microns

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Directed Energy Deposition Processes

Cited by 157 publications

References 6 publications

Titanium Alloy Repair with Wire-Feed Electron Beam Additive Manufacturing Technology

Titanium Alloy Repair with Wire-Feed Electron Beam Additive Manufacturing Technology

Application of Directed Energy Deposition-Based Additive Manufacturing in Repair

Polymer-derived SiOC replica of material extrusion-based 3-D printed plastics

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