Optimizing laser power of directed energy deposition process for homogeneous AISI M4 steel microstructure

Jardin, Ruben; Tuninetti, Víctor; Tchuindjang, Jérôme Tchoufack; Duchêne, Laurent; Hashemi, Neda; Tran, Hoang Son; Carrus, Raoul; Mertens, Anne; Habraken, Anne

doi:10.1016/j.optlastec.2023.109426

Cited by 10 publications

(6 citation statements)

References 58 publications

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“…The selected words "numerical parameters" underline the fact that in order to have compensated the thermal flow in the transversal direction, which is not taken into account in the 2D FE simulations, these parameters have lost their physical meaning and need careful identification to recover the experimental observations, including substrate temperature at thermocouples and melt pool size at the last layer. Note that further validations of the 2D FE computed temperature fields, such as the heterogeneity of the carbide type along the height of the bulk sample studied, as well as of the Vickers hardness profile and nano hardness information, were provided respectively within reference [5]. The present research highlights the fact that different sets of numerical parameters and associated results could be identified only if the thermocouple temperature measurements are exploited, or if poor accuracy is accepted within the identification methodology.…”

Section: Introductionmentioning

confidence: 92%

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Impact of Boundary Parameters Accuracy on Modeling of Directed Energy Deposition Thermal Field

Gallo,

Duchêne,

Quy Duc Pham

et al. 2024

Metals

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Within the large Additive Manufacturing (AM) process family, Directed Energy Deposition (DED) can be used to create low-cost prototypes and coatings, or to repair cracks. In the case of M4 HSS (High Speed Steel), a reliable computed temperature field during DED process allows the optimization of the substrate preheating temperature value and other process parameters. Such optimization is required to avoid failure during the process, as well as high residual stresses. If 3D DED simulations provide accurate thermal fields, they also induce huge computation time, which motivates simplifications. This article uses a 2D Finite Element (FE) model that decreases the computation cost through dividing the CPU time by around 100 in our studied case, but it needs some calibrations. As described, the identification of a correct data set solely based on local temperature measurements can lead to various sets of parameters with variations of up to 100%. In this study, the melt pool depth was used as an additional experimental measurement to identify the input data set, and a sensitivity analysis was conducted to estimate the impact of each identified parameter on the cooling rate and the melt pool dimension.

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Section: Introductionmentioning

confidence: 92%

“…DED has high potential in cladding uneven substrates. It reaches high cooling rates and generates fine microstructures [5]. If optimized, the process can achieve little distortion and high-quality deposits [6].…”

Section: Introductionmentioning

confidence: 99%

Impact of Boundary Parameters Accuracy on Modeling of Directed Energy Deposition Thermal Field

Gallo,

Duchêne,

Quy Duc Pham

et al. 2024

Metals

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“…Directed energy deposition (DED) is a cutting‐edge additive manufacturing (AM) technology that utilizes a laser heat source to melt metal powder onto the substrate surface, [ 6–8 ] resulting in the formation of a strong metallurgical bond. [ 9,10 ] Typically, a laser is utilized as the heat source for DED, owing to its superior performance characteristics such as high energy density, good stability, and a small thermal‐influenced region, [ 11 ] These qualities make it highly suitable for meeting the needs of engineering part remanufacturing and life extension.…”

Section: Introductionmentioning

confidence: 99%

“…[ 9,10 ] Typically, a laser is utilized as the heat source for DED, owing to its superior performance characteristics such as high energy density, good stability, and a small thermal‐influenced region, [ 11 ] These qualities make it highly suitable for meeting the needs of engineering part remanufacturing and life extension. [ 12,13 ] When utilizing laser DED technology to fabricate W6Mo5Cr4V2 alloy, the high cooling rate may result in a phase transition process that does not conform to conventional phase transition rules, [ 7,14 ] and carbide growth is inhibited. Consequently, the W6Mo5Cr4V2 alloy sample fabricated using laser DED technology exhibits finer carbides than those produced using traditional techniques.…”

Section: Introductionmentioning

confidence: 99%

Boosting Mechanical Properties of W6Mo5Cr4V2 Alloy Fabricated by Directed Energy Deposition Through Tempering Heat Treatment

Chen

Liu

Lei

et al. 2023

steel research int.

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The utilization of laser directed energy deposition (DED) for fabricating alloys offers the potential to customize their mechanical and physical properties, which cannot be achieved with traditional casting processes. In this work, DED adopted flat top laser was applied in the production of W6Mo5Cr4V2 alloy, a material widely used in industries such as mold‐making, double screw production, and crushing roller manufacturing. To minimize residual stress and potential defects, and enhance the performance of the deposited sample, it underwent a tempering heat treatment at 560°C for one hour. The deposited W6Mo5Cr4V2 alloy was found to be predominantly composed of martensite, carbide, and a minor amount of retained austenite, according to the analysis results. Upon tempering heat treatment, the retained austenite underwent a significant transformation into martensite, with secondary carbides precipitating and effectively reinforcing the mechanical properties of the W6Mo5Cr4V2 alloy. Furthermore, the microhardness value of the alloy was found to increase by 12% after tempering heat treatment. Both adhesive and abrasive wear were observed during the friction and wear process, resulting in a 10% reduction in friction coefficient, thereby significantly improving the wear resistance of the W6Mo5Cr4V2 alloy. The average tensile strength of the heat‐treated W6Mo5Cr4V2 sample was 762.34 MPa, which is higher than the average tensile strength of the deposited sample measured at 646.6 MPa. Notably, the tensile fracture displayed typical brittle characteristics.This article is protected by copyright. All rights reserved.

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“…Advanced manufacturing techniques such as powder metallurgy, selective laser melting (SLM), and computer-aided machining (CAM) have become widely adopted, enabling the precise production of metals with advanced properties [1][2][3][4]. However, that is not all-advanced numerical modeling and process optimization technologies allow for the improvement of manufacturing process parameters and waste minimization [5][6][7][8].…”

Section: Introductionmentioning

confidence: 99%

Characteristics of the Side Surfaces and Edges of Welded Wire Meshes Used in the Construction of Welded Slotted Screens

Bąk,

Wencel,

Wieczorek

2023

Materials

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Welded resistance slotted screens, also known as slotted screens, are a special type of screen primarily used for the filtration and separation of liquids and dust. They are characterized by slots with parallel geometry and precisely defined sizes. The quality of the side surfaces and edges of welded wires determines the durability of the slotted screens made from them. This article presents the results of tests for four types of wires: two types of working profile wires made from austenitic-ferritic steel (duplex) and two types of supporting cross wires made from ferritic steel. The wire surfaces were characterized using a profilometer and atomic force microscopy. Basic roughness parameters Ra, Rz, and SAD (surface area difference) were determined. Surface observations of the working profiles were conducted using scanning electron microscopy. These studies allowed for the characterization of the working wire surfaces used in the production of slotted screens. At work, the results of surface roughness were analyzed based on three measurement methods for wires used in the production of welded slot screens. These results allowed for the identification of the most reliable method for characterizing the surface condition of such products.

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Optimizing laser power of directed energy deposition process for homogeneous AISI M4 steel microstructure

Cited by 10 publications

References 58 publications

Impact of Boundary Parameters Accuracy on Modeling of Directed Energy Deposition Thermal Field

Impact of Boundary Parameters Accuracy on Modeling of Directed Energy Deposition Thermal Field

Boosting Mechanical Properties of W6Mo5Cr4V2 Alloy Fabricated by Directed Energy Deposition Through Tempering Heat Treatment

Characteristics of the Side Surfaces and Edges of Welded Wire Meshes Used in the Construction of Welded Slotted Screens

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