Experimental and numerical study of the influence of induction heating process on build rates Induction Heating-assisted laser Direct Metal Deposition (IH-DMD)

Dalaee, Mohammad; Gloor, Lars; Leinenbach, Christian; Wegener, Konrad

doi:10.1016/j.surfcoat.2019.125275

Cited by 27 publications

(14 citation statements)

References 9 publications

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“…To understand the increasing DE trend obtained by using IHCS, the interactions between the coatings, the EMF, and the substrate must be considered. While the coating is deposited, the EMF interacts not only with the substrate, but with the coating as well as other studies have shown [1][2][3]. Two consequences may arise from these interactions.…”

Section: Coating Characterizationmentioning

confidence: 95%

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Hybrid Additive Manufacturing Technology—Induction Heating Cold Spray

Ortiz-Fernandez

Jodoin

2021

Thermal Spray 2021: Proceedings From the International Thermal Spray Conference

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Cold Spray (CS) has gained special interest as a coating method due to the production of low oxide content deposits and solid-state deposition of powder material. This paper investigates the interaction between an electromagnetic field and cold-sprayed coatings produced using an induction heating cold spray (IHCS) system. It also investigates the role of the initial substrate surface temperature. The soft/hard material combination was used for depositing pure aluminum on Ti64 substrates. To assess the performance of the IHCS technique, deposition efficiency and adhesion and tensile strengths were used to characterize the hybrid technique. The results were compared to the traditional CS process. It was observed that the IHCS tensile samples exhibited almost three times the average elongation at break obtained by the traditional CS process. Intra-particle surface fracture was found in the samples produced by the hybrid process.

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Section: Coating Characterizationmentioning

confidence: 95%

“…Studies have shown that coupling an induction heating process with a coating method can positively influence the deposition process [1][2][3]. However, the use of induction heaters (IH) in the CS literature is scarce and limited.…”

Section: Introductionmentioning

confidence: 99%

Hybrid Additive Manufacturing Technology—Induction Heating Cold Spray

Ortiz-Fernandez

Jodoin

2021

Thermal Spray 2021: Proceedings From the International Thermal Spray Conference

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“…The length scale of the model domain ranges from less than a millimeter for the analysis of melt pool dynamics [ 5 ] to several centimeters or even meters where the development of the temperature field on the part scale is of interest [ 6 ]. For melt pool modeling of a single welding track, the symmetry of the process permits consideration of only one half of the track within the domain, in order to reduce computational costs [ 7 , 8 ]. According to Wei et al [ 9 ], heat sources can be defined as point or line heat sources for analytical models, and as surface or volumetric heat sources for numerical models.…”

Section: Introductionmentioning

confidence: 99%

Laser Remelting Process Simulation and Optimization for Additive Manufacturing of Nickel-Based Super Alloys

et al. 2021

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Nickel-based super alloys are popular for applications in the energy and aerospace industries due to their excellent corrosion and high-temperature resistance. Direct metal deposition (DMD) of nickel alloys has reached technology readiness for several applications, especially for the repair of turbomachinery components. However, issues related to part quality and defect formation during the DMD process still persist. Laser remelting can effectively prevent and repair defects during metal additive manufacturing (AM); however, very few studies have focused on numerical modeling and experimental process parameter optimization in this context. Therefore, the aim of this study is to investigate the effect of determining the remelting process parameters via numerical simulation and experimental analyses in order to optimize an industrial process chain for part repair by DMD. A heat conduction model analyzed 360 different process conditions, and the predicted melt geometry was compared with observations from a fluid flow model and experimental single tracks for selected reference conditions. Subsequently, the remelting process was applied to a demonstrator repair case. The results show that the models can well predict the melt pool shape and that the optimized remelting process increases the bonding quality between base and DMD materials. Therefore, DMD part fabrication and repair processes can benefit from the remelting step developed here.

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“…The productivity is essential in AM of large metallic components to make the laser DMD method economically beneficial for industries. In the previous publications [7,8], the potential integration of laser DMD technology with existing technologies was studied, aiming to enhance the deposition rate. However, the first and crucial step in this subject is to set the main processing parameters to obtain optimum parameter combinations, resulting in a maximum achievable deposition rate for the specific laser power.…”

Section: Introductionmentioning

confidence: 99%

Parameters Development for Optimum Deposition Rate in Laser DMD of Stainless Steel EN X3CrNiMo13-4

Dalaee

Cerrutti

Dey

et al. 2021

Lasers Manuf. Mater. Process.

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Laser Direct Metal Deposition (DMD) has been developed as a manufacturing process to deposit coatings on existing materials and proves advantageous in Additive Manufacturing (AM) of complex and precise components. However, it is necessary to carefully determine the proper process parameter combinations to make this method economically viable for industries. The intent of this study is to address enhancement in productivity of laser DMD of stainless steel EN X3CrNiMo13-4. Accordingly, the effects of the main laser process parameters of laser power P, scan speed v, powder flow rate $$\dot{\mathrm{m}}$$ m ˙ , and spot diameter s on track geometries and build-up rate are discussed. The regression analysis is conducted to derive correlations between the combined set of main parameters and deposition rate. The results show a good linear regression correlation of R2 >0.9 for the geometrical characteristic of aspect ratio, dilution, and deposition rate. The constructed processing map, using linear regression equations, presents proper process parameters selection in connection with deposition rate, aspect ratio, and dilution rate.

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Experimental and numerical study of the influence of induction heating process on build rates Induction Heating-assisted laser Direct Metal Deposition (IH-DMD)

Cited by 27 publications

References 9 publications

Hybrid Additive Manufacturing Technology—Induction Heating Cold Spray

Hybrid Additive Manufacturing Technology—Induction Heating Cold Spray

Laser Remelting Process Simulation and Optimization for Additive Manufacturing of Nickel-Based Super Alloys

Parameters Development for Optimum Deposition Rate in Laser DMD of Stainless Steel EN X3CrNiMo13-4

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