Partitioning of laser energy during directed energy deposition

Lia, Frederick; Park, Joshua; Tressler, J. F.; Martukanitz, R. P.

doi:10.1016/j.addma.2017.08.012

Cited by 35 publications

(21 citation statements)

References 10 publications

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“…Therefore, keeping track of how the initial heat source energy is distributed during the process will be beneficial in further improving the DED process to reduce energy loss and maximize energy for melting powders. Calorimetric measurements of the energy absorbed by the substrate (Q ABS ), energy absorbed by the powder (Q DEP ), energy reflected by the substrate (Q REF ), and energy lost by the powder (Q LOST ) due to evaporation and lack of fusion for DED of Ti-6Al-4V and Inconel were performed in the literature [77]. The important parameter is the bulk absorption coefficient (β), which gives the ratio of the energy for a particular component of energy (Q ABS , Q DEP , Q REF , or Q LOST ) with respect to the total energy supplied to the system (Q IN ).…”

Section: Energy Distribution In a Ded Systemmentioning

confidence: 99%

“…The important parameter is the bulk absorption coefficient (β), which gives the ratio of the energy for a particular component of energy (Q ABS , Q DEP , Q REF , or Q LOST ) with respect to the total energy supplied to the system (Q IN ). The energy balance equation is shown in Equation (2) and the corresponding bulk absorption coefficient, β, is presented in Equation (3) [77]:…”

Section: Energy Distribution In a Ded Systemmentioning

confidence: 99%

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State of the Art in Directed Energy Deposition: From Additive Manufacturing to Materials Design

2019

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Additive manufacturing (AM) is a new paradigm for the design and production of high-performance components for aerospace, medical, energy, and automotive applications. This review will exclusively cover directed energy deposition (DED)-AM, with a focus on the deposition of powder-feed based metal and alloy systems. This paper provides a comprehensive review on the classification of DED systems, process variables, process physics, modelling efforts, common defects, mechanical properties of DED parts, and quality control methods. To provide a practical framework to print different materials using DED, a process map using the linear heat input and powder feed rate as variables is constructed. Based on the process map, three different areas that are not optimized for DED are identified. These areas correspond to the formation of a lack of fusion, keyholing, and mixed mode porosity in the printed parts. In the final part of the paper, emerging applications of DED from repairing damaged parts to bulk combinatorial alloys design are discussed. This paper concludes with recommendations for future research in order to transform the technology from “form” to “function,” which can provide significant potential benefits to different industries.

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Section: Energy Distribution In a Ded Systemmentioning

confidence: 99%

Section: Energy Distribution In a Ded Systemmentioning

confidence: 99%

State of the Art in Directed Energy Deposition: From Additive Manufacturing to Materials Design

2019

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“…The degree of attenuation is unknown but expected to vary depending on the characteristics of the cloud, leading to irregularities with the deposited clads. Attenuation of the laser beam is an established phenomenon in DED (Lia et al , 2017) and is expected to be higher in case of powder particles with irregular shapes. Smaller powder particle sizes and high feeding rates increase the probability of forming the cloud, but its density varies randomly.…”

Section: Resultsmentioning

confidence: 99%

From mine to part: directed energy deposition of iron ore

Naesstroem

Brueckner

Kaplan

2021

RPJ

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Purpose This paper aims to gain an understanding of the behaviour of iron ore when melted by a laser beam in a continuous manner. This fundamental knowledge is essential to further develop additive manufacturing routes such as production of low cost parts and in-situ reduction of the ore during processing. Design/methodology/approach Blown powder directed energy deposition was used as the processing method. The process was observed through high-speed imaging, and computed tomography was used to analyse the specimens. Findings The experimental trials give preliminary results showing potential for the processability of iron ore for additive manufacturing. A large and stable melt pool is formed in spite of the inhomogeneous material used. Single and multilayer tracks could be deposited. Although smooth and even on the surface, the single layer tracks displayed porosity. In case of multilayered tracks, delamination from the substrate material and deformation can be seen. High-speed videos of the process reveal various process phenomena such as melting of ore powder during feeding, cloud formation, melt pool size, melt flow and spatter formation. Originality/value Very little literature is available that studies the possible use of ore in additive manufacturing. Although the process studied here is not industrially useable as is, it is a step towards processing cheap unprocessed material with a laser beam.

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“…In comparison with the other AM processes, DED has a unique position due to its potential to produce monolithic metal and functionally graded parts, as well as their repair [44]. Monolithic stainless steel, aluminum, titanium, nickel, and copper alloys have been already fabricated by DED process [4,[45][46][47][48][49]. However, functionally graded parts or bimetal joining are the main purposes of engineering technology science to obtain a predominated quality of products.…”

Section: Directed Energy Deposition (Ded)mentioning

confidence: 99%

Application of Directed Energy Deposition-Based Additive Manufacturing in Repair

et al. 2019

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In the circular economy, products, components, and materials are aimed to be kept at the utility and value all the lifetime. For this purpose, repair and remanufacturing are highly considered as proper techniques to return the value of the product during its life. Directed Energy Deposition (DED) is a very flexible type of additive manufacturing (AM), and among the AM techniques, it is most suitable for repairing and remanufacturing automotive and aerospace components. Its application allows damaged component to be repaired, and material lost in service to be replaced to restore the part to its original shape. In the past, tungsten inert gas welding was used as the main repair method. However, its heat affected zone is larger, and the quality is inferior. In comparison with the conventional welding processes, repair via DED has more advantages, including lower heat input, warpage and distortion, higher cooling rate, lower dilution rate, excellent metallurgical bonding between the deposited layers, high precision, and suitability for full automation. Hence, the proposed repairing method based on DED appears to be a capable method of repairing. Therefore, the focus of this study was to present an overview of the DED process and its role in the repairing of metallic components. The outcomes of this study confirm the significant capability of DED process as a repair and remanufacturing technology.

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Partitioning of laser energy during directed energy deposition

Cited by 35 publications

References 10 publications

State of the Art in Directed Energy Deposition: From Additive Manufacturing to Materials Design

State of the Art in Directed Energy Deposition: From Additive Manufacturing to Materials Design

From mine to part: directed energy deposition of iron ore

Application of Directed Energy Deposition-Based Additive Manufacturing in Repair

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