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Inside-laser material feeding laser cladding deposition (IMF-LCD) is a directed energy deposition technology featuring “hollow beam, annular spot, centered powder, and coaxial powder feeding.” IMF-LCD offers distinct advantages over traditional outside laser material feeding laser cladding deposition (OMF-LCD), such as a good laser-powder coupling effect, high powder utilization, high forming flexibility, uniform thermal field distribution in molten pools, and excellent forming surface quality. IMF-LCD would significantly improve forming efficiency and surface quality while it was applied to rapid direct manufacturing and repair of complex metallic parts compared to OMF-LCD. In this manuscript, the working principle of IMF-LCD technology is briefly introduced. Mostly, the research progress on heteromorphic structure parts fabricated by IMF-LCD was summarized, focusing on layered design, posture change, forming strategy optimization, and process parameter adjustment. The heteromorphic structure included a twisted thin-walled structure, variant height/width structure, overhanging structure, and closed structure. Based on the excellent characteristics of this technology, the exploration of high forming quality heteromorphic structural parts is carried out by changing the process parameters and forming processes such as the variable attitude stacking method, the conformal discrete layering method and the normal layering method, and the surface roughness is as low as 1.323 μm, the dimensional accuracy is as high as 1.6%. Simultaneously, the powder utilization rate of IMF-LCD reached 60%–80% on average, in accordance with the advantages of the laser-powder coupling effect. Finally, the remarkable research and application of IMF-LCD technology in high flexibility, high precision, high surface quality, and high material utilization would further promote the development of additive manufacturing with higher performance, higher quality, and lower cost in the future.
Inside-laser material feeding laser cladding deposition (IMF-LCD) is a directed energy deposition technology featuring “hollow beam, annular spot, centered powder, and coaxial powder feeding.” IMF-LCD offers distinct advantages over traditional outside laser material feeding laser cladding deposition (OMF-LCD), such as a good laser-powder coupling effect, high powder utilization, high forming flexibility, uniform thermal field distribution in molten pools, and excellent forming surface quality. IMF-LCD would significantly improve forming efficiency and surface quality while it was applied to rapid direct manufacturing and repair of complex metallic parts compared to OMF-LCD. In this manuscript, the working principle of IMF-LCD technology is briefly introduced. Mostly, the research progress on heteromorphic structure parts fabricated by IMF-LCD was summarized, focusing on layered design, posture change, forming strategy optimization, and process parameter adjustment. The heteromorphic structure included a twisted thin-walled structure, variant height/width structure, overhanging structure, and closed structure. Based on the excellent characteristics of this technology, the exploration of high forming quality heteromorphic structural parts is carried out by changing the process parameters and forming processes such as the variable attitude stacking method, the conformal discrete layering method and the normal layering method, and the surface roughness is as low as 1.323 μm, the dimensional accuracy is as high as 1.6%. Simultaneously, the powder utilization rate of IMF-LCD reached 60%–80% on average, in accordance with the advantages of the laser-powder coupling effect. Finally, the remarkable research and application of IMF-LCD technology in high flexibility, high precision, high surface quality, and high material utilization would further promote the development of additive manufacturing with higher performance, higher quality, and lower cost in the future.
In this paper, the deposition layer calculation model is proposed for laser-directed energy deposition (DED) with coaxial powder feeding by combining the powder feeding equation with the volume of fluid (VOF) method, and the single-channel IN718 forming process is simulated in real-time with moving boundary conditions in a fixed coordinate system and experimentally validated. Under single-layer single-channel deposition processing, the deposition height and width decreased by 57.1% and 21.6%, respectively, as the scanning speed increased from 8 mm/s to 14 mm/s. The calculated deposition height, width, and melt pool depth were in good agreement with the experimental results. Calculating the temperature field distribution of the single-layer double-channel deposition at an overlapping-rate of 30% yielded the temperature fluctuation pattern of the deposition at various lap moments. Under the influence of the thermal accumulation of the first deposition channel, the latent heat effect of the melt pool will cause the maximum surface temperature during overlap processing to be slightly lower than the maximum surface temperature during single channel processing; at the same time, under the influence of the high-temperature state of the overlap deposition channel during the scanning process, the first deposition channel will exhibit rewarming during the overlap scanning process. The deposition layer and temperature field of single-layer multi-channel laser deposition are modelled using this information. It has been proved that the model may be used to forecast deposition and temperature fields for intricate processing procedures. The study findings are significant for understanding the process mechanism of coaxial powder feeding laser-directed energy deposition in detail and optimizing the process.
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