Effect of layer thickness setting on deposition characteristics in direct energy deposition (DED) process

Shim, Do-Sik; Baek, Gyeong-Yun; Seo, Jin-Seon; Shin, Gwang-Yong; Kim, Kee-Poong; Lee, Ki-Yong

doi:10.1016/j.optlastec.2016.07.001

Cited by 124 publications

(34 citation statements)

References 14 publications

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“…Laser-Engineered Net Shaping (LENS) is a directed energy deposition method (DED). DED is commonly used for repair operations or to add additional material to existing components [ 1 , 2 , 3 , 4 , 5 ]. A nozzle is mounted on a multi-axis arm, which deposits melted material onto a specified surface, where it solidifies.…”

Section: Introductionmentioning

confidence: 99%

Fatigue Behavior of Porous Ti-6Al-4V Made by Laser-Engineered Net Shaping

et al. 2018

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The fatigue behavior and fracture mechanisms of additively manufactured Ti-6Al-4V specimens are investigated in this study. Three sets of testing samples were fabricated for the assessment of fatigue life. The first batch of samples was built by using Laser-Engineered Net Shaping (LENS) technology, a Direct Energy Deposition (DED) method. Internal voids and defects were induced in a second batch of samples by changing LENS machine processing parameters. Fatigue performance of these samples is compared to the wrought Ti-6Al-4V samples. The effects of machine-induced porosity are assessed on mechanical properties and results are presented in the form of SN curves for the three sets of samples. Fracture mechanisms are examined by using Scanning Electron Microscopy (SEM) to characterize the morphological characteristics of the failure surface. Different fracture surface morphologies are observed for porous and non-porous specimens due to the combination of head write speed and laser power. Formation of defects such as pores, unmelted regions, and gas entrapments affect the failure mechanisms in porous specimens. Non-porous specimens exhibit fatigue properties comparable with that of the wrought specimens, but porous specimens are found to show a tremendous reduced fatigue strength.

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Section: Introductionmentioning

confidence: 99%

Fatigue Behavior of Porous Ti-6Al-4V Made by Laser-Engineered Net Shaping

et al. 2018

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“…DED technology is a powder/wire feed process in which the powder/wire is delivered into the molten pool that is generated by a heat source. In fact, in DED, feeding of starting materials is simultaneously carried out with irradiation of a concentrated energy source (such as electrons beam, plasma arc or laser) on a certain area of the substrate, whereas in the PBF method, an already distributed powder bed is selectively fused [86]. At the same time, feedstock (Fig.…”

Section: Directed Energy Depositionmentioning

confidence: 99%

A Comprehensive Overview on the Latest Progress in the Additive Manufacturing of Metal Matrix Composites: Potential, Challenges, and Feasible Solutions

Dadkhah

Mosallanejad

Iuliano

et al. 2021

Acta Metall. Sin. (Engl. Lett.)

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Nowadays, as an emerging technology, additive manufacturing (AM) has received numerous attentions from researchers around the world. The method comprises layer-by-layer manufacturing of products according to the 3D CAD models of the objects. Among other things, AM is capable of producing metal matrix composites (MMCs). Hence, plenty of works in the literature are dedicated to developing different types of MMCs through AM processes. Hence, this paper provides a comprehensive overview on the latest research that has been carried out on the development of the powder-based AM manufactured MMCs from a scientific and technological viewpoint, aimed at highlighting the opportunities and challenges of this innovative manufacturing process. For instance, it is documented that AM is not only able to resolve the reinforcement/matrix bonding issues usually faced with during conventional manufacturing of MMCs, but also it is capable of producing functionally graded composites and geometrically complex objects. Furthermore, it provides the opportunity for a uniform distribution of the reinforcing phase in the metallic matrix and is able to produce composites using refractory metals thanks to the local heat source employed in the method. Despite the aforementioned advantages, there are still some challenges needing more attention from the researchers. Rapid cooling nature of the process, significantly different coefficient of expansion of the matrix and reinforcement, processability, and the lack of suitable parameters and standards for the production of defect-free AM MMCs seem to be among the most important issues to deal with in future works.

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“…DED, which is a manufacturing technique to build metallic and functional components, is a layer by layer AM process. In principle, in contrast to the powder bed fusion (PBF) processes in which a powder bed is selectively melted, DED is carried out by simultaneously feeding of powder or wire and a concentrated energy source [7]. In this method a melt pool is formed on the surface of the substrate or last deposited layer by using a relatively high powered laser, such as Nd:YAG or CO 2 , or other energy sources and at the same time powder is blown through the laser beam and into the melt pool.…”

Section: Introductionmentioning

confidence: 99%

An Overview of Additive Manufacturing of Titanium Components by Directed Energy Deposition: Microstructure and Mechanical Properties

et al. 2017

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The directed energy deposition (DED) process can be employed to build net shape components or prototypes starting from powder or wires, through a layer-by-layer process. This process provides an opportunity to fabricate complex shaped and functionally graded parts that can be utilized in different engineering applications. DED uses a laser as a focused heat source to melt the in-situ delivered powder or wire-shaped raw materials. In the past years extensive studies on DED have shown that this process has great potential in order to be used for (i) rapid prototyping of metallic parts, (ii) fabrication of complex and customized parts, (iii) repairing/cladding valuable components which cannot be repaired by other traditional techniques. However, the industrial adoption of this process is still challenging owing to the lack of knowledge on the mechanical performances of the constructed components and also on the trustworthiness/durability of engineering parts produced by DED. This manuscript provides an overview of the additive manufacturing (AM) of titanium alloys and focuses in particular on the mechanical properties and microstructure of components fabricated by DED.

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Effect of layer thickness setting on deposition characteristics in direct energy deposition (DED) process

Cited by 124 publications

References 14 publications

Fatigue Behavior of Porous Ti-6Al-4V Made by Laser-Engineered Net Shaping

Fatigue Behavior of Porous Ti-6Al-4V Made by Laser-Engineered Net Shaping

A Comprehensive Overview on the Latest Progress in the Additive Manufacturing of Metal Matrix Composites: Potential, Challenges, and Feasible Solutions

An Overview of Additive Manufacturing of Titanium Components by Directed Energy Deposition: Microstructure and Mechanical Properties

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