Laser-based Hybrid System for Inconel 718 part repairing

Mazzucato, Federico; Menerini, Marco; Valente, Anna

doi:10.1016/j.procir.2020.01.164

Cited by 5 publications

(2 citation statements)

References 14 publications

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“…However, a key difference distinguishes the two processes: welding involves the fusion of two parts to form a more intricate piece, whereas DED fabricates a singular complex component from the ground up, which may or may not necessitate joining or welding to other subcomponents. Another point of contrast between the two processes is the smaller Heat-Affected Zone (HAZ), associated with DED but not welding [77]. Another distinction lies in the control method; DED is consistently computer-controlled, ensuring uniform deposits, precision, and control over the melt pool shape, whereas welding can vary between manual and computer-controlled processes depending on the application.…”

Section: Directed Energy Depositionmentioning

confidence: 99%

Advancements in 3D Printing: Directed Energy Deposition Techniques, Defect Analysis, and Quality Monitoring

Imran,

Che Idris,

De Silva

et al. 2024

Technologies

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This paper provides a comprehensive analysis of recent advancements in additive manufacturing, a transformative approach to industrial production that allows for the layer-by-layer construction of complex parts directly from digital models. Focusing specifically on Directed Energy Deposition, it begins by clarifying the fundamental principles of metal additive manufacturing as defined by International Organization of Standardization and American Society for Testing and Materials standards, with an emphasis on laser- and powder-based methods that are pivotal to Directed Energy Deposition. It explores the critical process mechanisms that can lead to defect formation in the manufactured parts, offering in-depth insights into the factors that influence these outcomes. Additionally, the unique mechanisms of defect formation inherent to Directed Energy Deposition are examined in detail. The review also covers the current landscape of process evaluation and non-destructive testing methods essential for quality assurance, including both traditional and contemporary in situ monitoring techniques, with a particular focus given to advanced machine-vision-based methods for geometric analysis. Furthermore, the integration of process monitoring, multiphysics simulation models, and data analytics is discussed, charting a forward-looking roadmap for the development of Digital Twins in Laser–Powder-based Directed Energy Deposition. Finally, this review highlights critical research gaps and proposes directions for future research to enhance the accuracy and efficiency of Directed Energy Deposition systems.

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Section: Directed Energy Depositionmentioning

confidence: 99%

Advancements in 3D Printing: Directed Energy Deposition Techniques, Defect Analysis, and Quality Monitoring

Imran,

Che Idris,

De Silva

et al. 2024

Technologies

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“…In order to solve these constraints, hybrid manufacturing strategies have arisen. Nowadays, hybrid manufacturing strategies that combine L-DED and a posterior machining are widely used to increase the final accuracy and surface finish of the part [4]. Moreover, the industrial sector is facing a continuous evolution, thereby additive and subtractive hybrid manufacturing is being introduced to deal with difficult to machine materials.…”

Section: Introductionmentioning

confidence: 99%

Digital Testing of Hybrid Components Manufactured by L-DED and Forging

Murua De la Mata,

Arrizubieta Arrate,

Escudero

et al. 2023

KEM

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Manufacturing effectiveness is highly demanded in the aerospace industry; therefore, hybrid manufacturing technologies have gained considerable attention in order to overcome the limitations of a single manufacturing technology. Actually, the hybridisation of different manufacturing processes consists in taking advantage of the strengths of each process and compensating the weaknesses. In this work, the Laser Directed Energy Deposition (L-DED) process is hybridised with forging. The L-DED is an Additive Manufacturing technology which enables to add material on existing parts in order to add geometrical details or repair damaged areas. Thereby, the flexibility of the L-DED can be combined with the high-productivity and lower cost of the forging. A nickel-based superalloy employed in aeronautical applications is selected, the Inconel 718, which is suitable for high-temperature applications, such as the turbine casing of jet engines. Depending on the manufacturing process and final heat treatment, the Inconel 718 presents different properties. Hence, simulation tools are considered as a key element for the material properties characterization, where digital testing is becoming a fundamental pillar. Thermal and mechanical simulations with FEM enable the evaluation of the complete thermal history of the part and the resulting mechanical behaviour in-service conditions. In this work, the feasibility of hybridising forging and L-DED is studied. For this purpose, the resulting properties of the parts manufactured by each individual process are quantified and the interaction between both processes is analysed. Moreover, a test part is manufactured to show the hybridisation capabilities. Afterwards, to determine the behaviour of such demonstrator, a digital testing is performed by means of finite element modelling. Both thermal and structural analysis are carried out and the results obtained for the hybrid component are compared with those of an entirely forged part, focusing on a critical assessment of the performance of each manufacturing approach.

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