Laser-directed energy deposition of CuCrZr alloy: from statistical process parameter optimization to microstructural analysis

Zardoshtian, Ali; Ansari, Mazyar; Esmaeilzadeh, Reza; Keshavarzkermani, Ali; Jahed, Hamid; Toyserkani, Ehsan

doi:10.1007/s00170-023-11403-3

Cited by 4 publications

(7 citation statements)

References 34 publications

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“…However, when the laser power level exceeded 1000 W, the width began to slightly increase. This increase in melt pool width was further supported by Lee et al [106] and Zardoshtian et al [107], where more pronounced effects were observed when high levels of laser power were utilized. This can be attributed to the Gaussian distribution of high laser power, which results in a maximum temperature at the centre of the melt pool, with temperature disparities between the centre and edges of the melt pool leading to differences in surface tension.…”

Section: Powder Feed Ratesupporting

confidence: 55%

“…Many researchers have posited that there is a linear correlation between the size of the melt pool and laser power (W) [87,96,97,[103][104][105][106][107][108][109][110][111][112][113]. However, contradictory results were found in the literature when analysing the effect of laser power on the height of the melt pool, indicating that the relationship between these variables is not linear [86,[114][115][116].…”

Section: Laser Powermentioning

confidence: 99%

“…On the other hand, Srivastava et al [118] and Carrozza et al [86] observed that increasing the value of laser power results in a reduction in layer height for Ti-6Al-4V titanium alloy powders, while Saeedi et al [109] showed that the layer height increases with laser power with Nickel-Chromium (NiCr) and Titanium Carbide (TiC) alloy powder. Despite these varied findings, the general consensus is that higher laser power results in a larger melt pool size in various types of alloy powder [87,103,107,[110][111][112][113][114]. This holds true even for the Inconel 718, which was previously believed to be impervious to laser power [97,117], but further investigations discovered that both previous studies had utilised a high laser power of 350-2000 W. Another study conducted with the laser power ranging from 2500 to 3400 W indicated a reduction in melt pool height [108].…”

Section: Laser Powermentioning

confidence: 99%

“…Table 2 illustrates the effects of scan speed on the melt pool size. The majority of the studies concluded that increasing the scan speed would reduce the melt pool size due to the reduction in specific energy density on the region [87,96,103,105,107,108,111,113,115,121]. Contradictorily, Saeedi et al [109] discovered that the height of NiCr alloys tends to increase as the scan speed is elevated at a constant power.…”

Section: Scan Speedmentioning

confidence: 99%

See 3 more Smart Citations

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: Powder Feed Ratesupporting

confidence: 55%

Section: Laser Powermentioning

confidence: 99%

Section: Laser Powermentioning

confidence: 99%

Section: Scan Speedmentioning

confidence: 99%

See 2 more Smart Citations

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

Imran,

Che Idris,

De Silva

et al. 2024

Technologies

View full text Add to dashboard Cite

show abstract

“…To address this requirement, LDED stands as the sole choice among AM techniques that has been reported the production of sizeable components with intricate geometries, specifically utilizing the CuCrZr alloy [23][24][25]. Zardoshtian et al [26] conducted a study on LDED processing of CuCrZr alloy in the single-track scale. First, they optimized the main process parameters using a two-step statistical approach and multiple DOEs.…”

Section: Introductionmentioning

confidence: 99%

On the Processability and Microstructural Evolution of CuCrZr in Multilayer Laser-Directed Energy Deposition Additive Manufacturing via Statistical and Experimental Methods

Zardoshtian,

Esmaeilizadeh,

Ansari

et al. 2023

JMMP

Self Cite

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Laser-directed energy deposition (LDED) is a promising technology for coating, repairing, and building near-net-shape 3D structures. However, the processing of copper alloys, specifically, has presented a significant challenge due to their low laser absorptivity at the 1060 nm laser wavelength and high thermal conductivity. This study undertook a methodical examination by employing a 2 kW disk laser, operating at a wavelength of 1064 nm, and a coaxial nozzle head to comprehensively examine the processability of the highly conductive CuCrZr alloy for expanding the range of materials that can be successfully processed using LDED. The investigation focuses not only on optimizing the input process parameters that are the laser power, scanning speed, powder feed rate, and overlap ratio, but also on planning the toolpath trajectory, as these factors were found to exert a substantial influence on processability, geometrical accuracy, and the occurrence of defects such as lack of fusion. The optimal toolpath trajectory discovered involved implementing a zigzag strategy combined with a 90° rotation of the scanning direction. Additionally, a start point rotation was considered between each layer to even out the deposition of the layers. Moreover, a contour with a radial path at the corners was introduced to enhance the overall trajectory. Based on the hierarchal experimental study, the appropriate ranges for the key process parameters that leads to 99.99% relative density have been identified. They were found to be from 1100 up to 2000 W for the laser power (P), and from 0.003 up to 0.016 g/mm for the amount of powder that is fed to the melt pool distance (F/V). Regarding the influence of process parameters on the microstructure of the samples with equal deposition height, it was observed that varying combinations of process parameters within the optimal processing window resulted in variations in grain size ranging from 105 to 215 µm.

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Prediction models and multi-objective optimization of the single deposited tracks in laser direct metal deposition of 316L stainless steel

Doan Tat,

Le,

Duong Van

2024

Manufacturing Rev.

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Laser direct metal deposition (LDMD) is a metal additive manufacturing process, which uses a laser source to melt metal powder and deposit the molten metal into the part layer-by-layer through a nozzle. With suitable process parameters and setting conditions, a component can be fabricated with a full density. In this process, the shape of single tracks is a key indicator, which directly prescribes the quality of the process and the fabricated component. To fabricate a complex component, especially that with thin-wall structures with free of defects, controlling the single tracks' geometry and the understanding on the effects of the process parameters are essential. Therefore, this article focuses on studying the effects of process variables on single tracks' attributes in the LDMD process of SS316L and identifying the optimum variables for the deposition of SS316L thin wall structures. The observed results indicated that, among the process parameters (the scanning speed Vs, the laser power Pl, and the powder feed rate fp), Pl exhibits the highest impact contribution to the models of the deposited track width w and the deposited track penetration p with a contribution of 71.83% and 87.68%, respectively. Vs exhibits the highest contribution to the models of the deposited track height h a contribution of 49.86%. On the other hand, fp shows an insignificant impact contribution to the w and p models. All the developed models feature a high prediction accuracy with the values of determination coefficients R2 of 97.89%, 97.08%, 99.11% for w, h, and p, respectively, indicating that they can be used to prediction w, h, and p with high confidence and precision levels. Moreover, the optimization results achieved by different methods (i.e., GRA, TOPSIS, and PSO+TOPSIS) demonstrated that the PSO and TOPSIS combination can be used to find out the most optimal process parameters (i.e., Vs = 6 mm/s, Pl = 263.63 W, and fp = 18 g/min) to build thin-walled structures in SS316L by LDMD.

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Laser-directed energy deposition of CuCrZr alloy: from statistical process parameter optimization to microstructural analysis

Cited by 4 publications

References 34 publications

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

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

On the Processability and Microstructural Evolution of CuCrZr in Multilayer Laser-Directed Energy Deposition Additive Manufacturing via Statistical and Experimental Methods

Prediction models and multi-objective optimization of the single deposited tracks in laser direct metal deposition of 316L stainless steel

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