Influence of High-Productivity Process Parameters on the Surface Quality and Residual Stress State of AISI 316L Components Produced by Directed Energy Deposition

Piscopo, Gabriele; Salmi, Alessandro; Atzeni, Eleonora

doi:10.1007/s11665-021-05954-3

Cited by 16 publications

(17 citation statements)

References 56 publications

(3 reference statements)

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“…Then, Balichakra, et al [151], during the deposition of a γ titanium aluminide thin wall, showed that residual stresses were almost independent from the travel speed and laser power. On the other hand, anther author showed that lower residual stresses were obtained when higher laser power [152] and lower travel speed [149,152,153] were used.…”

Section: Residual Stressmentioning

confidence: 99%

An Overview of Physical Phenomena Involved in the Laser Powder Directed Energy Deposition Process

Piscopo¹,

Atzeni²,

Saboori³

et al. 2022

Preprint

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Laser Powder Directed Energy Deposition (LP-DED) is an Additive Manufacturing process in which a laser beam is used to generate a melt pool onto a substrate. The additional material, in form of powder material, is fed into the generated melt pool and a raised track is obtained. The LP-DED process is very powerful for different applications such as the repair operations and the production of functionally graded material, however the application is still limited and one of the main reasons is related to the lack of knowledge in the physics of the process mechanisms. The process is influenced by a huge number of parameters and three main mechanisms can be identi-fied. These mechanisms are the powder flow, the generation of the molten pool and the solidifica-tion process and for each of these mechanisms the process parameters have a different relevance. In this paper, a review of the main mechanisms and the relationship between the process parame-ters and the outcome of each step of the process is presented.

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Section: Residual Stressmentioning

confidence: 99%

An Overview of Physical Phenomena Involved in the Laser Powder Directed Energy Deposition Process

Piscopo¹,

Atzeni²,

Saboori³

et al. 2022

Preprint

View full text Add to dashboard Cite

show abstract

“…From the literature, it is possible to observe that, despite the high level of industrialization of powder bed processes, they can be used only for the production of small/medium components, with a maximum size of 400 mm [13,14]. DED processes allow overcoming this problem since the deposited dimension can reach up to 3000 mm in size.…”

Section: Introductionmentioning

confidence: 99%

Current research and industrial application of laser powder directed energy deposition

Piscopo

Iuliano

2022

Int J Adv Manuf Technol

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Additive Manufacturing (AM) technologies are recognized as the future of the manufacturing industry thanks to their possibilities in terms of shape design, part functionality, and material efficiency. The use of AM technologies in many industrial sectors is growing, also due to the increasing knowledge regarding the AM processes and the characteristics of the final part. One of the most promising AM techniques is the Directed Energy Deposition (DED) that uses a thermal source to generate a melt pool on a substrate into which metal powder is injected. The potentialities of DED technology are the ability to process large build volumes (> 1000 mm in size), the ability to deliver the material directly into the melt pool, the possibility to repair existing parts, and the opportunity to change the material during the building process, thus creating functionally graded material. In this paper, a review of the industrial applications of Laser Powder Directed Energy Deposition (LP-DED) is presented. Three main applications are identified in repairing, designed material, and production. Despite the enormous advantages of LP-DED, from the literature, it emerges that the most relevant application refers to the repairing process of high-value components.

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“…The characteristic high solidification rates encountered in additive manufacturing processes typically result in the formation of supersaturated solid solutions, making a postprocess heat treatment necessary [5]. However, in additive manufacturing, adjustments of the process parameters may induce in-process precipitation reactions [6][7][8][9], phase transformations [10,11], affect residual stress in the printed parts [12][13][14][15], and modify the grain structure and texture [5,16,17]. Thus, mechanical properties, e.g., tensile and fatigue strength, can be significantly altered by the utilization of different process parameters [14,[18][19][20][21].…”

Section: Introductionmentioning

confidence: 99%

“…However, in additive manufacturing, adjustments of the process parameters may induce in-process precipitation reactions [6][7][8][9], phase transformations [10,11], affect residual stress in the printed parts [12][13][14][15], and modify the grain structure and texture [5,16,17]. Thus, mechanical properties, e.g., tensile and fatigue strength, can be significantly altered by the utilization of different process parameters [14,[18][19][20][21]. Process parameters also have a decisive impact on defect formation, the final density, and thus, the material integrity.…”

Section: Introductionmentioning

confidence: 99%

Additive Manufacturing Potentials of High Performance Ferritic (HiperFer) Steels

et al. 2022

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In the present study, the first tailored steel based on HiperFer (high-performance ferrite) was developed specifically for the additive manufacturing process. This steel demonstrates its full performance potential when produced via additive manufacturing, e.g., through a high cooling rate, an in-build heat treatment, a tailored microstructure and counteracts potential process-induced defects (e.g. pores and cavities) via “active” crack-inhibiting mechanisms, such as thermomechanically induced precipitation of intermetallic (Fe,Cr,Si)2(W,Nb) Laves phase particles. Two governing mechanisms can be used to accomplish this: (I) “in-build heat treatment” by utilizing the “temper bead effect” during additive manufacturing and (II) “dynamic strengthening” under cyclic, plastic deformation at high temperature. To achieve this, the first HiperFerAM (additive manufacturing) model alloy with high precipitation kinetics was developed. Initial mechanical tests indicated great potential in terms of the tensile strength, elongation at rupture and minimum creep rate. During the thermomechanical loading, global sub-grain formation occurred in the HiperFerAM, which refined the grain structure and allowed for higher plastic deformation, and consequently, increased the elongation at rupture. The additive manufacturing process also enabled the reduction of grain size to a region, which has not been accessible by conventional processing routes (casting, rolling, heat treatment) so far.

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Influence of High-Productivity Process Parameters on the Surface Quality and Residual Stress State of AISI 316L Components Produced by Directed Energy Deposition

Cited by 16 publications

References 56 publications

An Overview of Physical Phenomena Involved in the Laser Powder Directed Energy Deposition Process

An Overview of Physical Phenomena Involved in the Laser Powder Directed Energy Deposition Process

Current research and industrial application of laser powder directed energy deposition

Additive Manufacturing Potentials of High Performance Ferritic (HiperFer) Steels

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