Assessing the quality and productivity of laser cladding and direct energy deposition: Guidelines for researchers

Powell, John; Koti, Daniel; Garmendia, Xabier; Voisey, K.T.

doi:10.2351/7.0000897

Journal of Laser Applications

2023

DOI: 10.2351/7.0000897

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Assessing the quality and productivity of laser cladding and direct energy deposition: Guidelines for researchers

John Powell

Daniel Koti

Xabier Garmendia³

et al.

Abstract: This paper provides guidelines and advice to researchers and engineers in the field of laser cladding and related direct energy deposition techniques to help establish a standardized approach to quality assessment and productivity metrics. Factors considered are deposit geometry, porosity, cracking, dilution, build-up/coverage rate, and powder catchment efficiency.

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Cited by 6 publications

References 71 publications

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Enhancing productivity and efficiency in conventional laser metal deposition process for Inconel 718 - part I: the effects of the process parameters

Maffia,

Chiappini,

Maggiani

et al. 2023

Int J Adv Manuf Technol

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The sustainable energy transition has spurred the development of technologies that minimize material and energy waste, such as additive manufacturing (AM). Laser metal deposition (LMD) is a promising AM technique, but its complexity and limited automation hinder its implementation in production chains. To enhance productivity, the high deposition rate LMD (HDR-LMD) technology has been developed, requiring advanced equipment and powerful laser sources. In contrast, the conventional LMD (C-LMD) process is simpler and less expensive to implement. This study aims to optimize the productivity and efficiency of C-LMD by adjusting laser power, scan speed, powder feed rate, and standoff distance on Inconel 718 single tracks. An innovative approach eliminates the need for cutting specimens to evaluate single tracks, allowing comprehensive geometric and performance characterization with limited operator involvement, making the analysis quicker and more robust. An extensive experimental campaign was conducted to examine the influence of process parameters on track geometry, productivity, and efficiency. A multi-objective optimization procedure identified parameter combinations maximizing productivity while maintaining high efficiency and desirable clad shape. The study attained deposition rates ranging from 700 to 800 g/h, with powder catchment efficiency ranging between 75 and 90%. These results were achieved using parameters including 1775 W of laser power, scan speeds ranging from 960 to 1140 mm/min, powder feed rates between 810 and 1080 g/h, and standoff distance of 9 mm. The study also clearly indicated that further potential for improving C-LMD process performance may be possible. The findings gathered in this paper are the base for the further optimization presented in the second part of the work, which is focused on multi-pass multi-layer and reaches deposition rates of 1500 g/h, promoting the implementation of C-LMD process at industrial level.

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Enhancing productivity and efficiency in conventional laser metal deposition process for Inconel 718 - part I: the effects of the process parameters

Maffia,

Chiappini,

Maggiani

et al. 2023

Int J Adv Manuf Technol

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Enhancing productivity and efficiency in conventional laser metal deposition process for Inconel 718 – Part II: advancing the process performance

Maffia,

Chiappini,

Maggiani

et al. 2023

Int J Adv Manuf Technol

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This paper is the second part of a work focused on optimizing the performance of conventional Laser Metal Deposition (C-LMD) process for Inconel 718 (IN718). In Part I, through an extensive experimental campaign on single tracks, the interplay between process parameters and their impact on the deposition rate, powder catchment efficiency, and clad geometry is examined. The parameters investigated include laser power, scan speed, powder feed rate, and standoff distance. By systematically adjusting these parameters, the aim is to identify optimal conditions that maximize productivity while maintaining a favorable clad shape for multi-pass multi-layer depositions. Part II starts from the findings and results of Part I by continuing the optimization on thick wall structures. These are utilized to assess the effect of 3D geometrical process parameters, specifically hatch spacing and Z-step, on process performance and stability. Based on the findings, further optimization procedure is presented, pushing the boundaries of the C-LMD process for IN718. By fine-tuning the process parameters, the capability of the C-LMD process to deposit fully dense IN718 with a productivity of 1500 g/h and a powder catchment efficiency of 70% is demonstrated. These results highlight the potential of C-LMD as a viable manufacturing technique for efficiently fabricating large components. Overall, this study contributes to a deeper understanding of the relationship between process parameters and performance in C-LMD for IN718. The insights gained from this research can guide the development of efficient and cost-effective LMD strategies, facilitating the practical implementation of this process in various industries.

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Gas-particle-heat dynamic coupling simulation in directed energy deposition

Zhang,

Chen,

Gao

et al. 2024

International Journal of Mechanical Sciences

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Assessing the quality and productivity of laser cladding and direct energy deposition: Guidelines for researchers

Cited by 6 publications

References 71 publications

Enhancing productivity and efficiency in conventional laser metal deposition process for Inconel 718 - part I: the effects of the process parameters

Enhancing productivity and efficiency in conventional laser metal deposition process for Inconel 718 - part I: the effects of the process parameters

Enhancing productivity and efficiency in conventional laser metal deposition process for Inconel 718 – Part II: advancing the process performance

Gas-particle-heat dynamic coupling simulation in directed energy deposition

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