Laser-based directed energy deposition (DED-LB) of advanced materials

Svetlizky, David; Zheng, Baolong; Vyatskikh, Alexandra L.; Das, Mitun; Bose, Susmita; Bandyopadhyay, Amit; Schoenung, Julie M.; Lavernia, Enrique J.; Eliaz, Noam

doi:10.1016/j.msea.2022.142967

Cited by 144 publications

(37 citation statements)

References 551 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…For instance, different powder materials can be premixed prior to the L-DED process [ 61 ]. If higher flexibility is needed, multiple hoppers can be employed to facilitate the in situ modification of the composition of the feedstock [ 22 ]. By individually adjusting the powder mass flow rate of each constituent, the composition of the melt pool can by precisely tuned [ 71 ].…”

Section: Additive Manufacturing Of Multi-materials Structuresmentioning

confidence: 99%

“…The concept of HEAs involves a design based on multiple elements in equimolar or near-equimolar ratios [ 77 ]. As a result, the possible combinations for the alloy design are exponentially increased [ 22 ]. It has been reported that HEAs are capable of providing a distinct combination of properties including high strength, hardness, wear, and corrosion or thermal resistance [ 78 ].…”

Section: Additive Manufacturing Of Multi-materials Structuresmentioning

confidence: 99%

See 1 more Smart Citation

Latest Developments to Manufacture Metal Matrix Composites and Functionally Graded Materials through AM: A State-of-the-Art Review

et al. 2023

View full text Add to dashboard Cite

Multi-material structure fabrication has the potential to address some critical challenges in today’s industrial paradigm. While conventional manufacturing processes cannot deliver multi-material structures in a single operation, additive manufacturing (AM) has come up as an appealing alternative. In particular, laser-directed energy deposition (L-DED) is preferred for multi-material AM. The most relevant applications envisioned for multi-material LDED are alloy design, metal matrix composites (MMC), and functionally graded materials (FGM). Nonetheless, there are still some issues that need to be faced before multi-material L-DED is ready for industrial use. Driven by this need, in this literature review, the suitability of L-DED for multi-material component fabrication is first demonstrated. Then, the main defects associated with multi-material LDED and current opportunities and challenges in the field are reported. In view of the industrial relevance of high-performance coatings as tools to mitigate wear, emphasis is placed on the development of MMCs and FGMs. The identified challenges include—but are not limited to—tightly controlling the composition of the multi-material powder mixture injected into the melt pool; understanding the influence of the thermal history of the process on microstructural aspects, including the interactions between constituents; and studying the in-service behaviours of MMCs and FGMs with regard to their durability and failure modes.

show abstract

Section: Additive Manufacturing Of Multi-materials Structuresmentioning

confidence: 99%

Section: Additive Manufacturing Of Multi-materials Structuresmentioning

confidence: 99%

Latest Developments to Manufacture Metal Matrix Composites and Functionally Graded Materials through AM: A State-of-the-Art Review

et al. 2023

View full text Add to dashboard Cite

show abstract

“…In the DED process, the metal powder fed by a powder nozzle will be melted by a moving laser in real time and deposited on the substrate successive, and a single-track construction will be completed. One or more overlying layers in a 3D structure consisting of a large number of tracks [1,2] . Due to its flexibility and convenience, DED technology has been widely employed in aerospace [3] , medical [4] , biological sciences [5] , and other fields to provide customized manufacturing services.…”

Section: Introductionmentioning

confidence: 99%

Numerical simulation on melt pool and solidification in the direct energy deposition process of GH3536 powder superalloy

Liu

Liu²,

Li³

et al. 2023

Preprint

View full text Add to dashboard Cite

In the direct energy deposition (DED) process, the highly energetic laser, rapid melting, and solidification processes lead to complex heat transfer and flow phenomena. A three-dimensional finite element model (FEM) is established to study the effect of process parameters on the melt pool and solidification quality during the DED process. The heat transfer, fluid flow, and solidification in the DED process of the GH3536 superalloy are studied. By investigating the effects of laser power, scanning speed, and feed rate on the morphology of melt pool and interlayer fusion, the appropriate input parameters for GH3536 are obtained. Temperature gradient and solidification rate obtained in transient thermal distribution are applied to predict the quality and morphology of the solidified structure at the cut-off point. Results show that high laser power and low scanning speed or feed rate will enlarge the melt pool. Well-solidified microstructure frequently appears in the middle of the parameter set; focusing on the enlargement of the melt pool is not the best strategy. The correlation between feed rate and laser power is not obvious. The minimum threshold for scanning speed is found at a given feed rate. When the scanning rate is below the threshold, abnormal morphology of the melt pool and irregular solidification structures will occur. The laser power and scanning speed range suitable for the GH3536 superalloy are summarized, and the undesirable and possibly fluctuating parameters are marked. The middle part of the parameter set is recommended for the feed rate.

show abstract

“…Two widely used powder-bed systems are Selective Laser Melting (SLM shown in Figure 2.9) and Electron Beam Melting (EBM). The powder-fed systems like Directed Energy Deposition (DED), uses a focused energy source, such as laser to melt the powder which is being deposited by the nozzle [65] (Figure 2.10). In recent times DED have become popular because of its capability to allow the adding of material to an already existing part [66], and the combination of different materials produced in the same build [65,67].…”

Section: Metal Additive Manufacturing (Am)mentioning

confidence: 99%

“…The powder-fed systems like Directed Energy Deposition (DED), uses a focused energy source, such as laser to melt the powder which is being deposited by the nozzle [65] (Figure 2.10). In recent times DED have become popular because of its capability to allow the adding of material to an already existing part [66], and the combination of different materials produced in the same build [65,67]. For this reason, DED is most widely used to modify or repair the damaged parts for many manufacturing industries [68][69][70].…”

Section: Metal Additive Manufacturing (Am)mentioning

confidence: 99%

Surface engineering of metals via metallographic etching for microstructural characterization

Jain¹

View full text Add to dashboard Cite

Laser-based directed energy deposition (DED-LB) of advanced materials

Cited by 144 publications

References 551 publications

Latest Developments to Manufacture Metal Matrix Composites and Functionally Graded Materials through AM: A State-of-the-Art Review

Latest Developments to Manufacture Metal Matrix Composites and Functionally Graded Materials through AM: A State-of-the-Art Review

Numerical simulation on melt pool and solidification in the direct energy deposition process of GH3536 powder superalloy

Surface engineering of metals via metallographic etching for microstructural characterization

Contact Info

Product

Resources

About