Towards hybrid laser-arc based directed energy deposition: Understanding bead formation through mathematical modeling for additive manufacturing

Kapil, Angshuman; Suga, Tetsuo; Tanaka, Manabu; Sharma, Abhay

doi:10.1016/j.jmapro.2022.02.027

Cited by 18 publications

(7 citation statements)

References 21 publications

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“…Finally, an external pulsed laser stimulates the molten pool to produce an oscillation effect, slowing down the solidification process and promoting microstructural refinement in the deposition layer. Figure 11(a) presents a typical custom integration equipment for pulse laser-assisted WAAM assembled by Kapil et al [90]. This setup includes a digital inverter control type metal active gas (MAG) power source operating with an Ar-20% CO 2 shielding gas at a flow rate of 25 l min −1 (DP500, Daihen Corporation), and a fiber laser oscillator (IPG make).…”

Section: Pulse Laser Assisted Am Technologymentioning

confidence: 99%

Performance-control-orientated hybrid metal additive manufacturing technologies: state of the art, challenges, and future trends

Lv,

Liang,

et al. 2024

Int. J. Extrem. Manuf.

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Metal additive manufacturing (AM) technologies have made significant progress in the basic theoretical field since their invention in the 1970s. However, performance instability during continuous processing, such as thermal history, residual stress accumulation, and columnar grain epitaxial growth, consistently hinders their broad application in standardized industrial production. To overcome these challenges, performance-control-oriented hybrid AM (HAM) technologies have been introduced. These technologies, by leveraging external auxiliary processes, aim to regulate microstructural evolution and mechanical properties during metal AM. In this context, HAM technologies for molten pool regulation and solidified material deformation are identified as energy field-assisted AM (EFed AM, e.g., ultrasonic, electromagnetic, heat, etc.) technologies and interlayer plastic deformation-assisted AM (IPDed AM, e.g., laser shock peening, rolling, ultrasonic peening, friction stir process, etc.) technologies, respectively. A detailed and systematic review of performance-control-oriented HAM technologies is then provided. This review covers the influence of external energy fields on the melting, flow, and solidification behavior of materials, and the regulatory effects of interlayer plastic deformation on grain refinement, nucleation, and recrystallization. Furthermore, the role of performance-control-oriented HAM technologies in managing residual stress conversion, metallurgical defect closure, mechanical property improvement, and anisotropy regulation is thoroughly reviewed and discussed. The review concludes with an analysis of future development trends in EFed AM and IPDed AM technologies.

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Section: Pulse Laser Assisted Am Technologymentioning

confidence: 99%

Performance-control-orientated hybrid metal additive manufacturing technologies: state of the art, challenges, and future trends

Lv,

Liang,

et al. 2024

Int. J. Extrem. Manuf.

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“…Conventionally, the weld bead profiles are modelled by fitting standard geometric shapes such as parabola [85] or cosine [86]. The new WAAM variants, such as laser-arc hybrid [87] or twin-wire welding [88], do not fit the standard geometric shapes and require the application of computational methods to determine the shape of the weld bead. For instance, the characteristic coefficients in the following bead profile equation for laser-arc hybrid DED are obtained by a numerical method [87].…”

Section: Modelling Of Large-size Elements In Ammentioning

confidence: 99%

“…The new WAAM variants, such as laser-arc hybrid [87] or twin-wire welding [88], do not fit the standard geometric shapes and require the application of computational methods to determine the shape of the weld bead. For instance, the characteristic coefficients in the following bead profile equation for laser-arc hybrid DED are obtained by a numerical method [87]. The welding process parameters, mainly the welding current and travel speed that determine the shape and size of the weld bead, also determine the heat input per unit volume and thereby affect the distortion, residual stress, and microstructure.…”

Section: Modelling Of Large-size Elements In Ammentioning

confidence: 99%

“…Theoretically, the materials that are welded can also be printed using WAAM; however, converting welding equipment into an AM machine needs several modifications, such as additivesubtractive AM, where the deposited material is intermediately or eventually machined [158]. In some research works, different welding processes were hybridised to enhance the range of WAAM, for instance, friction stir welding and arc welding [159] or laser and arc welding [87].…”

Section: Hybrid Manufacturingmentioning

confidence: 99%

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A Survey on Process Modelling, Innovation, Design, and Material Characterisation in Additive Manufacturing

Hassani

Emami

Tjahjowidodo

et al. 2023

Digital Manufacturing Technology

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The unique design freedom offered by additive manufacturing (AM) technologies enables engineers to develop more innovative products with relatively lower costs within a shorter period of processing time in comparison with conventional manufacturing methods. On the other hand, the unique capabilities of AM have created a platform for researchers to combine several engineering methods with the new manufacturing technique to grow industrial applications as well as resolve the existing issues with AM processes. Understanding the research values that AM offers academic environments, this paper performs a systematic survey on AM-related research topics in the fields of mechanical engineering and materials science that have attracted much attention from research teams over the last few years. These topics, namely process modelling in AM, innovative research in AM, generative design by AM, material characterisation in AM processes, and finally, design for additive manufacturing (DfAM), are notably investigated through this study.

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“…Derimow et al [116] proposed a predictive mathematical model to simulate the thermal characteristics of simple layers of Laserdeposited Ti-6Al-4V for additive manufacturing in aerospace and biomedical applications. Kapil et al [117] also developed a mathematical model for simulation of the formation of hybridlike deposited layers via welding arc. In both cases, the error was not quanti ed when the experimental results were compared with the proposed model.…”

Section: Techniques For Process Simulation In Hmppmentioning

confidence: 99%

Hybrid manufacturing process planning with predictive approach: a comprehensive literature review

Velázquez

Simon²,

Helleno³

2022

Preprint

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The hybrid manufacturing has attracted industrial community interest due to its ability to produce functional parts with varied geometries, using different types of materials in the most varied applications. As with most manufacturing processes, before executing the hybrid process for the manufacture of a certain geometry, it is important to make a proper process planning that allows having an integral and proactive view of the operation. This work aims to synthesize through a systematic literature review (SLR) the state of the art on hybrid manufacturing process planning (HMPP) models with predictive approach. Three SLRs were developed to extract the articles of interest (2012-2022) from Science Direct, Springer Link, and Web of Science databases. PRISMA method was used to gather the papers and oriented the qualitative and quantitative analysis. Snowballing technique was used to gather articles of interest out of the period defined. Literature review showed that there is still no consensus between existing HMPP models, regarding all the activities necessary to ensure proper operation. In addition, the developed models have a limitation regarding the inclusion of a process simulation step. The simulation step on the existing models, does not allow to proactively check whether the experimental process conditions are adequate to ensure the manufacture of the modeled geometry before running the hybrid manufacturing process. An efficient simulation step would ensure a predictive approach to operation performance and would imply the reduction of geometric deviations without the need for excessive experimentation, reducing material consumption, manufacturing time, and resulting in a better deposition strategy. Using computational and statistical methods as support for decision-making in the process will allow the processing and analysis of data to assertively direct the structuring of a robust model for HMPP with predictive approach. A differentiated, more complete, and comprehensive process planning model is a relevant study opportunity for future research. This paper contributes to the theory development since it identifies and analyzes the existing HMPP models, highlights important gaps on the subject, and proposes insights for future development.

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Towards hybrid laser-arc based directed energy deposition: Understanding bead formation through mathematical modeling for additive manufacturing

Cited by 18 publications

References 21 publications

Performance-control-orientated hybrid metal additive manufacturing technologies: state of the art, challenges, and future trends

Performance-control-orientated hybrid metal additive manufacturing technologies: state of the art, challenges, and future trends

A Survey on Process Modelling, Innovation, Design, and Material Characterisation in Additive Manufacturing

Hybrid manufacturing process planning with predictive approach: a comprehensive literature review

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