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Journal articles on the topic 'Directed Energy Deposition Additive Manufacturing'

Author: Grafiati

Published: 31 January 2023

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1

Böß, Volker, Berend Denkena, Marc-André Dittrich, Talash Malek, and Sven Friebe. "Dexel-Based Simulation of Directed Energy Deposition Additive Manufacturing." Journal of Manufacturing and Materials Processing 5, no. 1 (January 11, 2021): 9. http://dx.doi.org/10.3390/jmmp5010009.

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Additive manufacturing is typically a flexible alternative to conventional manufacturing processes. However, manufacturing costs increase due to the effort required to experimentally determine optimum process parameters for customized products or small batches. Therefore, simulation models are needed in order to reduce the amount of effort necessary for experimental testing. For this purpose, a novel technological simulation method for directed energy deposition additive manufacturing is presented here. The Dexel-based simulation allows modeling of additive manufacturing of varying geometric shapes by considering multi-axis machine tool kinematics and local process conditions. The simulation approach can be combined with the simulation of subtractive processes, which enables integrated digital process chains.

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2

Böß, Volker, Berend Denkena, Marc-André Dittrich, Talash Malek, and Sven Friebe. "Dexel-Based Simulation of Directed Energy Deposition Additive Manufacturing." Journal of Manufacturing and Materials Processing 5, no. 1 (January 11, 2021): 9. http://dx.doi.org/10.3390/jmmp5010009.

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Additive manufacturing is typically a flexible alternative to conventional manufacturing processes. However, manufacturing costs increase due to the effort required to experimentally determine optimum process parameters for customized products or small batches. Therefore, simulation models are needed in order to reduce the amount of effort necessary for experimental testing. For this purpose, a novel technological simulation method for directed energy deposition additive manufacturing is presented here. The Dexel-based simulation allows modeling of additive manufacturing of varying geometric shapes by considering multi-axis machine tool kinematics and local process conditions. The simulation approach can be combined with the simulation of subtractive processes, which enables integrated digital process chains.

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3

Chen, Y., S. Clark, A. C. L. Leung, L. Sinclair, S. Marussi, R. Atwood, T. Connoley, M. Jones, G. Baxter, and P. D. Lee. "Melt pool morphology in directed energy deposition additive manufacturing process." IOP Conference Series: Materials Science and Engineering 861 (June 13, 2020): 012012. http://dx.doi.org/10.1088/1757-899x/861/1/012012.

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4

Saboori, Abdollah, Alberta Aversa, Giulio Marchese, Sara Biamino, Mariangela Lombardi, and Paolo Fino. "Application of Directed Energy Deposition-Based Additive Manufacturing in Repair." Applied Sciences 9, no. 16 (August 13, 2019): 3316. http://dx.doi.org/10.3390/app9163316.

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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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Hauser, Tobias, Raven T. Reisch, Tobias Kamps, Alexander F. H. Kaplan, and Joerg Volpp. "Acoustic emissions in directed energy deposition processes." International Journal of Advanced Manufacturing Technology 119, no. 5-6 (January 7, 2022): 3517–32. http://dx.doi.org/10.1007/s00170-021-08598-8.

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AbstractAcoustic emissions in directed energy deposition processes such as wire arc additive manufacturing and directed energy deposition with laser beam/metal are investigated within this work, as many insights about the process can be gained from this. In both processes, experienced operators can hear whether a process is running stable or not. Therefore, different experiments for stable and unstable processes with common process anomalies were carried out, and the acoustic emissions as well as process camera images were captured. Thereby, it was found that stable processes show a consistent mean intensity in the acoustic emissions for both processes. For wire arc additive manufacturing, it was found that by the Mel spectrum, a specific spectrum adapted to human hearing, the occurrence of different process anomalies can be detected. The main acoustic source in wire arc additive manufacturing is the plasma expansion of the arc. The acoustic emissions and the occurring process anomalies are mainly correlating with the size of the arc because that is essentially the ionized volume leading to the air pressure which causes the acoustic emissions. For directed energy deposition with laser beam/metal, it was found that by the Mel spectrum, the occurrence of an unstable process can also be detected. The main acoustic emissions are created by the interaction between the powder and the laser beam because the powder particles create an air pressure through the expansion of the particles from the solid state to the liquid state when these particles are melted. These findings can be used to achieve an in situ quality assurance by an in-process analysis of the acoustic emissions.

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Kelly, J. P., J. W. Elmer, F. J. Ryerson, J. R. I. Lee, and J. J. Haslam. "Directed energy deposition additive manufacturing of functionally graded Al-W composites." Additive Manufacturing 39 (March 2021): 101845. http://dx.doi.org/10.1016/j.addma.2021.101845.

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7

Heigel, Jarred C., Pan Michaleris, and Todd A. Palmer. "Measurement of forced surface convection in directed energy deposition additive manufacturing." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 230, no. 7 (October 30, 2015): 1295–308. http://dx.doi.org/10.1177/0954405415599928.

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8

Haley, James C., Baolong Zheng, Umberto Scipioni Bertoli, Alexander D. Dupuy, Julie M. Schoenung, and Enrique J. Lavernia. "Working distance passive stability in laser directed energy deposition additive manufacturing." Materials & Design 161 (January 2019): 86–94. http://dx.doi.org/10.1016/j.matdes.2018.11.021.

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9

Salmi, Mika. "Additive Manufacturing Processes in Medical Applications." Materials 14, no. 1 (January 3, 2021): 191. http://dx.doi.org/10.3390/ma14010191.

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Additive manufacturing (AM, 3D printing) is used in many fields and different industries. In the medical and dental field, every patient is unique and, therefore, AM has significant potential in personalized and customized solutions. This review explores what additive manufacturing processes and materials are utilized in medical and dental applications, especially focusing on processes that are less commonly used. The processes are categorized in ISO/ASTM process classes: powder bed fusion, material extrusion, VAT photopolymerization, material jetting, binder jetting, sheet lamination and directed energy deposition combined with classification of medical applications of AM. Based on the findings, it seems that directed energy deposition is utilized rarely only in implants and sheet lamination rarely for medical models or phantoms. Powder bed fusion, material extrusion and VAT photopolymerization are utilized in all categories. Material jetting is not used for implants and biomanufacturing, and binder jetting is not utilized for tools, instruments and parts for medical devices. The most common materials are thermoplastics, photopolymers and metals such as titanium alloys. If standard terminology of AM would be followed, this would allow a more systematic review of the utilization of different AM processes. Current development in binder jetting would allow more possibilities in the future.

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10

Biegler, Max, Jiahan Wang, Lukas Kaiser, and Michael Rethmeier. "Automated Tool‐Path Generation for Rapid Manufacturing of Additive Manufacturing Directed Energy Deposition Geometries." steel research international 91, no. 11 (May 8, 2020): 2000017. http://dx.doi.org/10.1002/srin.202000017.

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11

dos Santos Paes, Luiz Eduardo, Henrique Santos Ferreira, Milton Pereira, Fábio Antônio Xavier, Walter Lindolfo Weingaertner, and Louriel Oliveira Vilarinho. "Modeling layer geometry in directed energy deposition with laser for additive manufacturing." Surface and Coatings Technology 409 (March 2021): 126897. http://dx.doi.org/10.1016/j.surfcoat.2021.126897.

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12

Dillkötter, David, Johann Stoppok, Magnus Thiele, Cemal Esen, and Martin Mönnigmann. "Model-based temperature offset compensation for additive manufacturing by directed energy deposition." IFAC-PapersOnLine 53, no. 2 (2020): 11812–17. http://dx.doi.org/10.1016/j.ifacol.2020.12.691.

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13

Paul, A. C., A. N. Jinoop, C. P. Paul, P. Deogiri, and K. S. Bindra. "Investigating build geometry characteristics during laser directed energy deposition based additive manufacturing." Journal of Laser Applications 32, no. 4 (November 2020): 042002. http://dx.doi.org/10.2351/7.0000004.

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14

Guo, Bojing, Yashan Zhang, Zhongsheng Yang, Dingcong Cui, Feng He, Junjie Li, Zhijun Wang, Xin Lin, and Jincheng Wang. "Cracking mechanism of Hastelloy X superalloy during directed energy deposition additive manufacturing." Additive Manufacturing 55 (July 2022): 102792. http://dx.doi.org/10.1016/j.addma.2022.102792.

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15

Groden, C., Kellen D. Traxel, Ali Afrouzian, E. Nyberg, and A. Bandyopadhyay. "Inconel 718-W7Ni3Fe bimetallic structures using directed energy deposition-based additive manufacturing." Virtual and Physical Prototyping 17, no. 2 (January 17, 2022): 170–80. http://dx.doi.org/10.1080/17452759.2022.2025673.

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16

Xu, Jing, Xizhi Gu, Donghong Ding, Zengxi Pan, and Ken Chen. "A review of slicing methods for directed energy deposition based additive manufacturing." Rapid Prototyping Journal 24, no. 6 (August 13, 2018): 1012–25. http://dx.doi.org/10.1108/rpj-10-2017-0196.

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Purpose The purpose of this paper is to systematically review the published slicing methods for additive manufacturing (AM), especially the multi-direction and non-layerwise slicing methods, which are particularly suitable for the directed energy deposition (DED) process to improve the surface quality and eliminate the usage of support structures. Design/methodology/approach In this paper, the published slicing methods are clarified into three categories: the traditional slicing methods (e.g. the basic and adaptive slicing methods) performed in the powder bed fusion (PBF) system, the multi-direction slicing methods and non-layerwise slicing methods used in DED systems. The traditional slicing methods are reviewed only briefly because a review article already exists for them, and the latter two slicing methods are reviewed comprehensively with further discussion and outlook. Findings A few traditional slicing approaches were developed in the literature, including basic and adaptive slicing methods. These methods are efficient and robust when they are performed in the PBF system. However, they are retarded in the DED process because costly support structures are required to sustain overhanging parts and their surface quality and contour accuracy are not satisfactory. This limitation has led to the development of various multi-direction and non-layerwise slicing methods to improve the surface quality and enable the production of overhangs with minimum supports. Originality/value An original review of the AM slicing methods is provided in this paper. For the traditional slicing methods and the multi-direction and non-layerwise slicing method, the published slicing strategies are discussed and compared. Recommendations for future slicing work are also provided.

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17

Chadha, Utkarsh, Senthil Kumaran Selvaraj, Aakrit Sharma Lamsal, Yashwanth Maddini, Abhishek Krishna Ravinuthala, Bhawana Choudhary, Anirudh Mishra, et al. "Directed Energy Deposition via Artificial Intelligence-Enabled Approaches." Complexity 2022 (September 30, 2022): 1–32. http://dx.doi.org/10.1155/2022/2767371.

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Additive manufacturing (AM) has been gaining pace, replacing traditional manufacturing methods. Moreover, artificial intelligence and machine learning implementation has increased for further applications and advancements. This review extensively follows all the research work and the contemporary signs of progress in the directed energy deposition (DED) process. All types of DED systems, feed materials, energy sources, and shielding gases used in this process are also analyzed in detail. Implementing artificial intelligence (AI) in the DED process to make the process less human-dependent and control the complicated aspects has been rigorously reviewed. Various AI techniques like neural networks, gradient boosted decision trees, support vector machines, and Gaussian process techniques can achieve the desired aim. These models implemented in the DED process have been trained for high-precision products and superior quality monitoring.

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Naesstroem, Himani, Frank Brueckner, and Alexander F. H. Kaplan. "From mine to part: directed energy deposition of iron ore." Rapid Prototyping Journal 27, no. 11 (July 19, 2021): 37–42. http://dx.doi.org/10.1108/rpj-10-2020-0243.

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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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19

Kiran, Abhilash, Ying Li, Josef Hodek, Michal Brázda, Miroslav Urbánek, and Jan Džugan. "Heat Source Modeling and Residual Stress Analysis for Metal Directed Energy Deposition Additive Manufacturing." Materials 15, no. 7 (March 30, 2022): 2545. http://dx.doi.org/10.3390/ma15072545.

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The advancement in additive manufacturing encourages the development of simplified tools for deep and swift research of the technology. Several approaches were developed to reduce the complexity of multi-track modeling for additive manufacturing. In the present work, a simple heat source model called concentrated heat source was evaluated for single- and multi-track deposition for directed energy deposition. The concentrated heat source model was compared with the widely accepted Goldak heat source model. The concentrated heat source does not require melt pool dimension measurement for thermal model simulation. Thus, it reduces the considerable time for preprocessing. The shape of the melt pool and temperature contour around the heat source was analyzed for single-track deposition. A good agreement was noticed for the concentrated heat source model melt pool, with an experimentally determined melt pool, using an optical microscope. Two heat source models were applied to multi-track 3D solid structure thermo-mechanical simulation. The results of the two models, for thermal history and residual stress, were compared with experimentally determined data. A good agreement was found for both models. The concentrated heat source model reported less than the half the computational time required for the Goldak model. The validated model, for 3D solid structure thermo-mechanical simulation, was used to analyze thermal stress evolution during the deposition process. The material deposition on the base plate at room temperature results in lower peak temperatures in the layers near the base plate. Consequently, the higher thermal stress in the layers near the base plate was found, compared to the upper layers during the deposition process.

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20

Doux, Adrien, and Vincent Philippe. "Thermomechanical modeling of IN718 alloy directed energy deposition process." MATEC Web of Conferences 304 (2019): 01023. http://dx.doi.org/10.1051/matecconf/201930401023.

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Directed Energy Deposition (DED) Additive Manufacturing (AM) processes have a great potential to be used as cost-effective and efficient repairing and re-manufacturing processes for aerospace components such as turbine blades and landing gears. The AMOS project intends to connect repair and re-manufacturing strategies with design through accurate DED process simulation and novel multi-disciplinary design optimisation (MDO) methods. The ultimate goal is to reduce aerospace component weaknesses at design stage and prolong their lifecycles. DED AM processes are multi-physical phenomena involving high laser power melting powder or wire on a substrate. An experimental heat source has been calibrated using a heat transfer analysis of IN718 laser and powder AM on a sample part. Residual stresses and final distortion are also computed using thermal field and the evolving part distortion at each increment. Multiple hypotheses have been considered model the molten pool creation on the Heat Affected Zone (HAZ).

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21

Xie, Jichang, Haifei Lu, Jinzhong Lu, Xinling Song, Shikai Wu, and Jianbo Lei. "Additive manufacturing of tungsten using directed energy deposition for potential nuclear fusion application." Surface and Coatings Technology 409 (March 2021): 126884. http://dx.doi.org/10.1016/j.surfcoat.2021.126884.

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22

Zhang, Xinchang, Wei Li, and Frank Liou. "Additive manufacturing of cobalt-based alloy on tool steel by directed energy deposition." Optics & Laser Technology 148 (April 2022): 107738. http://dx.doi.org/10.1016/j.optlastec.2021.107738.

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23

Liu, Peipei, Kiyoon Yi, Ikgeun Jeon, and Hoon Sohn. "Porosity inspection in directed energy deposition additive manufacturing based on transient thermoreflectance measurement." NDT & E International 122 (September 2021): 102491. http://dx.doi.org/10.1016/j.ndteint.2021.102491.

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24

Chen, Yunhui, Samuel J. Clark, David M. Collins, Sebastian Marussi, Simon A. Hunt, Danielle M. Fenech, Thomas Connolley, et al. "Correlative Synchrotron X-ray Imaging and Diffraction of Directed Energy Deposition Additive Manufacturing." Acta Materialia 209 (May 2021): 116777. http://dx.doi.org/10.1016/j.actamat.2021.116777.

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25

YAO, Xin-xin, Jian-yu LI, Yi-fei WANG, Xiang GAO, and Zhao ZHANG. "Numerical simulation of powder effect on solidification in directed energy deposition additive manufacturing." Transactions of Nonferrous Metals Society of China 31, no. 9 (September 2021): 2871–84. http://dx.doi.org/10.1016/s1003-6326(21)65700-x.

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26

Binega, Eden, Liu Yang, Hoon Sohn, and Jack C. P. Cheng. "Online geometry monitoring during directed energy deposition additive manufacturing using laser line scanning." Precision Engineering 73 (January 2022): 104–14. http://dx.doi.org/10.1016/j.precisioneng.2021.09.005.

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27

Kiran, Abhilash, Josef Hodek, Jaroslav Vavřík, Miroslav Urbánek, and Jan Džugan. "Numerical Simulation Development and Computational Optimization for Directed Energy Deposition Additive Manufacturing Process." Materials 13, no. 11 (June 11, 2020): 2666. http://dx.doi.org/10.3390/ma13112666.

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The rapid growth of Additive Manufacturing (AM) in the past decade has demonstrated a significant potential in cost-effective production with a superior quality product. A numerical simulation is a steep way to learn and improve the product quality, life cycle, and production cost. To cope with the growing AM field, researchers are exploring different techniques, methods, models to simulate the AM process efficiently. The goal is to develop a thermo-mechanical weld model for the Directed Energy Deposition (DED) process for 316L stainless steel at an efficient computational cost targeting to model large AM parts in residual stress calculation. To adapt the weld model to the DED simulation, single and multi-track thermal simulations were carried out. Numerical results were validated by the DED experiment. A good agreement was found between predicted temperature trends for numerical simulation and experimental results. A large number of weld tracks in the 3D solid AM parts make the finite element process simulation challenging in terms of computational time and large amounts of data management. The method of activating elements layer by layer and introducing heat in a cyclic manner called a thermal cycle heat input was applied. Thermal cycle heat input reduces the computational time considerably. The numerical results were compared to the experimental data for thermal and residual stress analyses. A lumping of layers strategy was implemented to reduce further computational time. The different number of lumping layers was analyzed to define the limit of lumping to retain accuracy in the residual stress calculation. The lumped layers residual stress calculation was validated by the contour cut method in the deposited sample. Thermal behavior and residual stress prediction for the different numbers of a lumped layer were examined and reported computational time reduction.

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Biegler, Max, Beatrix A. M. Elsner, Benjamin Graf, and Michael Rethmeier. "Geometric distortion-compensation via transient numerical simulation for directed energy deposition additive manufacturing." Science and Technology of Welding and Joining 25, no. 6 (March 24, 2020): 468–75. http://dx.doi.org/10.1080/13621718.2020.1743927.

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29

Melia, Michael A., Hai-Duy A. Nguyen, Jeffrey M. Rodelas, and Eric J. Schindelholz. "Corrosion properties of 304L stainless steel made by directed energy deposition additive manufacturing." Corrosion Science 152 (May 2019): 20–30. http://dx.doi.org/10.1016/j.corsci.2019.02.029.

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Weisz-Patrault, Daniel. "Fast simulation of temperature and phase transitions in directed energy deposition additive manufacturing." Additive Manufacturing 31 (January 2020): 100990. http://dx.doi.org/10.1016/j.addma.2019.100990.

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Khodabakhshi, F., M. H. Farshidianfar, S. Bakhshivash, A. P. Gerlich, and A. Khajepour. "Dissimilar metals deposition by directed energy based on powder-fed laser additive manufacturing." Journal of Manufacturing Processes 43 (July 2019): 83–97. http://dx.doi.org/10.1016/j.jmapro.2019.05.018.

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Gouveia, Joana R., Sara M. Pinto, Sara Campos, João R. Matos, Catarina Costa, Thiago Assis Dutra, Sílvia Esteves, and Luís Oliveira. "Life Cycle Assessment of a Circularity Case Study Using Additive Manufacturing." Sustainability 14, no. 15 (August 3, 2022): 9557. http://dx.doi.org/10.3390/su14159557.

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Currently, considering the rising concern in climate change, there is a clear necessity for technologies that can prolong the useful life of products through the ability to repair, re-manufacture and refurbish. As such, additive manufacturing has been a subject of research due to its design and resource consumption capabilities. However, there is a lack of more detailed information regarding environmental performances, especially in Directed Energy Deposition technology. The present paper presents a life-cycle assessment of the production and use of Directed Energy Deposition, making use of foreground data to build a life-cycle inventory and quantify the potential impacts. The equipment is analyzed for its refurbishment capabilities on an obsolete mold , and compared with the environmental impact of producing a new mold through conventional technology. The compiled inventory with detailed and primary information will enrich the current literature on this technology. The impact results show that the robot, deposition table and security cell are the most relevant subsystems for the system production impacts. In the refurbishment analysis, the refurbished mold part has lower impacts than the conventionally produced, thus showing that there is great potential in using additive manufacturing for circular economy loops.

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Nakajima, Kenya, Marc Leparoux, Hiroki Kurita, Briac Lanfant, Di Cui, Masahito Watanabe, Takenobu Sato, and Fumio Narita. "Additive Manufacturing of Magnetostrictive Fe–Co Alloys." Materials 15, no. 3 (January 18, 2022): 709. http://dx.doi.org/10.3390/ma15030709.

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Fe–Co alloys are attracting attention as magnetostrictive materials for energy harvesting and sensor applications. This work investigated the magnetostriction characteristics and crystal structure of additive-manufactured Fe–Co alloys using directed energy deposition. The additive-manufactured Fe–Co parts tended to exhibit better magnetostrictive performance than the hot-rolled Fe–Co alloy. The anisotropy energy ΔK1 for the Fe–Co bulk, prepared under a power of 300 W (referred to as bulk−300 W), was larger than for the rolled sample. For the bulk−300 W sample in a particular plane, the piezomagnetic constant d was large, irrespective of the direction of the magnetic field. Elongated voids that formed during additive manufacturing changed the magnetostrictive behavior in a direction perpendicular to these voids. Magnetic property measurements showed that the coercivity decreased. Since sensors should be highly responsive, Fe–Co three-dimensional parts produced via additive manufacturing can be applied as force sensors.

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Chen, Yitao, Xinchang Zhang, Mohammad Masud Parvez, and Frank Liou. "A Review on Metallic Alloys Fabrication Using Elemental Powder Blends by Laser Powder Directed Energy Deposition Process." Materials 13, no. 16 (August 12, 2020): 3562. http://dx.doi.org/10.3390/ma13163562.

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The laser powder directed energy deposition process is a metal additive manufacturing technique, which can fabricate metal parts with high geometric and material flexibility. The unique feature of in-situ powder feeding makes it possible to customize the elemental composition using elemental powder mixture during the fabrication process. Thus, it can be potentially applied to synthesize industrial alloys with low cost, modify alloys with different powder mixtures, and design novel alloys with location-dependent properties using elemental powder blends as feedstocks. This paper provides an overview of using a laser powder directed energy deposition method to fabricate various types of alloys by feeding elemental powder blends. At first, the advantage of laser powder directed energy deposition in manufacturing metal alloys is described in detail. Then, the state-of-the-art research and development in alloys fabricated by laser powder directed energy deposition through a mix of elemental powders in multiple categories is reviewed. Finally, critical technical challenges, mainly in composition control are discussed for future development.

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Choron, Damien, Serge Naveos, Marc Thomas, Johan Petit, and Didier Boisselier. "Direct Laser Additive Manufacturing of TiAl Intermetallic Compound by Powder Directed Energy Deposition (DED)." MATEC Web of Conferences 321 (2020): 03020. http://dx.doi.org/10.1051/matecconf/202032103020.

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Directed Energy Deposition of the commercial intermetallic Ti-48Al-2Cr-2Nb alloy was investigated. The CLAD® process is dependent on multiple parameters, which were successfully optimised through several experiments, including series of beads, small blocks, and massive blocks, under argon atmosphere. The use of adapted temperature management leads to massive blocks manufacturing that bear no apparent macroscopic defects, such as cracks, which are generally observed in this brittle material due to strong temperature cycling during the manufacturing. The microstructure and geometrical parameters were characterised by scanning electron microscopy (SEM). This process generates an ultra-fine and anisotropic microstructure, which is restored to a homogeneous duplex microstructure by a subsequent heat-treatment. Mechanical characterisation is in progress and will be used to validate the soundness of the materials produced in these conditions.

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36

Dass, Adrita, and Atieh Moridi. "State of the Art in Directed Energy Deposition: From Additive Manufacturing to Materials Design." Coatings 9, no. 7 (June 29, 2019): 418. http://dx.doi.org/10.3390/coatings9070418.

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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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37

Lee, Yukyeong, Eun Sung Kim, Se-Ho Chun, Jae Bok Seol, Hyokyung Sung, Jung Seok Oh, Hyoung Seop Kim, Taekyung Lee, Tae-Hyun Nam, and Jung Gi Kim. "Additive Manufacturing Optimization of Directed Energy Deposition-Processed Ti-6Al-4V Alloy using Energy Density and Powder Deposition Density." Journal of Korean Powder Metallurgy Institute 28, no. 6 (December 30, 2021): 491–96. http://dx.doi.org/10.4150/kpmi.2021.28.6.491.

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Haley, James, Clay Leach, Brian Jordan, Ryan Dehoff, and Vincent Paquit. "In-situ digital image correlation and thermal monitoring in directed energy deposition additive manufacturing." Optics Express 29, no. 7 (March 16, 2021): 9927. http://dx.doi.org/10.1364/oe.416659.

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Beghini, Lauren L., Michael Stender, Daniel Moser, Bradley L. Trembacki, Michael G. Veilleux, and Kurtis R. Ford. "A coupled fluid-mechanical workflow to simulate the directed energy deposition additive manufacturing process." Computational Mechanics 67, no. 4 (March 11, 2021): 1041–57. http://dx.doi.org/10.1007/s00466-020-01960-9.

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Sommer, Niklas, Philipp Kluge, Florian Stredak, Sascha Eigler, Horst Hill, Thomas Niendorf, and Stefan Böhm. "Additive Manufacturing of Compositionally-Graded AISI 316L to CoCrMo Structures by Directed Energy Deposition." Crystals 11, no. 9 (August 30, 2021): 1043. http://dx.doi.org/10.3390/cryst11091043.

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In the present study, compositionally-graded structures of AISI 316L and CoCrMo alloy are manufactured by powder-based laser-beam directed energy deposition (DED-LB). Through a process-integrated adjustment of powder flow, in situ alloying of the two materials becomes feasible. Thus, a sharp and a smooth transition with a mixture of both alloys can be realized. In order to investigate the phase formation during in situ alloying, a simulation approach considering equilibrium calculations is employed. The findings reveal that a precise compositional as well as functional gradation of the two alloys is possible. Thereby, the chemical composition can be directly correlated with the specimen hardness. Moreover, phases, which are identified by equilibrium calculations, can also be observed experimentally using scanning electron microscopy (SEM) and energy-dispersive X-ray-spectroscopy (EDS). Electron backscatter diffraction (EBSD) reveals epitaxial grain growth across the sharp transition region with a pronounced <001>-texture, while the smooth transition acts as nucleus for the growth of new grains with <101>-orientation. In light of envisaged applications in the biomedical sector, the present investigation demonstrates the high potential of an AISI 316L/CoCrMo alloy material combination.

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Zhang, Xinchang, Tan Pan, Yitao Chen, Lan Li, Yunlu Zhang, and Frank Liou. "Additive manufacturing of copper-stainless steel hybrid components using laser-aided directed energy deposition." Journal of Materials Science & Technology 80 (July 2021): 100–116. http://dx.doi.org/10.1016/j.jmst.2020.11.048.

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Stender, Michael E., Lauren L. Beghini, Joshua D. Sugar, Michael G. Veilleux, Samuel R. Subia, Thale R. Smith, Christopher W. San Marchi, Arthur A. Brown, and Daryl J. Dagel. "A thermal-mechanical finite element workflow for directed energy deposition additive manufacturing process modeling." Additive Manufacturing 21 (May 2018): 556–66. http://dx.doi.org/10.1016/j.addma.2018.04.012.

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Zhang, Z., P. Ge, T. Li, L. E. Lindgren, W. W. Liu, G. Z. Zhao, and X. Guo. "Electromagnetic wave-based analysis of laser–particle interactions in directed energy deposition additive manufacturing." Additive Manufacturing 34 (August 2020): 101284. http://dx.doi.org/10.1016/j.addma.2020.101284.

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Yadav, S., C. P. Paul, A. N. Jinoop, A. K. Rai, and K. S. Bindra. "Laser Directed Energy Deposition based Additive Manufacturing of Copper: Process Development and Material Characterizations." Journal of Manufacturing Processes 58 (October 2020): 984–97. http://dx.doi.org/10.1016/j.jmapro.2020.09.008.

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Furumoto, Tatsuaki. "Special Issue on Additive Manufacturing with Metals." International Journal of Automation Technology 13, no. 3 (May 5, 2019): 329. http://dx.doi.org/10.20965/ijat.2019.p0329.

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Additive manufacturing (AM) with metals is currently one of the most promising techniques for 3D-printed structures, as it has tremendous potential to produce complex, lightweight, and functionally-optimized parts. The medical, aerospace, and automotive industries are some of the many expected to reap particular benefits from the ability to produce high-quality models with reduced manufacturing costs and lead times. The main advantages of AM with metals are the flexibility of the process and the wide variety of metal materials that are available. Various materials, including steel, titanium, aluminum alloys, and nickel-based alloys, can be employed to produce end products. The objective of this special issue is to collect recent research works focusing on AM with metals. This issue includes 5 papers covering the following topics: ===danraku===- Powder bed fusion (PBF) ===danraku===- Directed energy deposition (DED) ===danraku===- Wire and arc-based AM (WAAM) ===danraku===- Binder jetting (BJT) ===danraku===- Fused deposition modeling (FDM) This issue is expected to help readers understand recent developments in AM, leading to further research. We deeply appreciate the contributions of all authors and thank the reviewers for their incisive efforts.

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Aydogan, Beytullah, and Himanshu Sahasrabudhe. "Enabling Multi-Material Structures of Co-Based Superalloy Using Laser Directed Energy Deposition Additive Manufacturing." Metals 11, no. 11 (October 27, 2021): 1717. http://dx.doi.org/10.3390/met11111717.

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Cobalt superalloys such as Tribaloys are widely used in environments that involve high temperatures, corrosion, and wear degradation. Additive manufacturing (AM) processes have been investigated for fabricating Co-based alloys due to design flexibility and efficient materials usage. AM processes are suitable for reducing the manufacturing steps and subsequently reducing manufacturing costs by incorporating multi-materials. Laser directed energy deposition (laser DED) is a suitable AM process for fabricating Co-based alloys. T800 is one of the commercially available Tribaloys that is strengthened through Laves phases and of interest to diverse engineering fields. However, the high content of the Laves phase makes the alloy prone to brittle fracture. In this study, a Ni-20%Cr alloy was used to improve the fabricability of the T800 alloy via laser DED. Different mixture compositions (20%, 30%, 40% NiCr by weight) were investigated. The multi-material T800 + NiCr alloys were heat treated at two different temperatures. These alloy chemistries were characterized for their microstructural, phase, and mechanical properties in the as-fabricated and heat-treated conditions. SEM and XRD characterization indicated the stabilization of ductile phases and homogenization of the Laves phases after laser DED fabrication and heat treatment. In conclusion, the NiCr addition improved the fabricability and structural integrity of the T800 alloy.

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Chaturvedi, Mukti, Elena Scutelnicu, Carmen Catalina Rusu, Luigi Renato Mistodie, Danut Mihailescu, and Arungalai Vendan Subbiah. "Wire Arc Additive Manufacturing: Review on Recent Findings and Challenges in Industrial Applications and Materials Characterization." Metals 11, no. 6 (June 9, 2021): 939. http://dx.doi.org/10.3390/met11060939.

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Wire arc additive manufacturing (WAAM) is a fusion manufacturing process in which the heat energy of an electric arc is employed for melting the electrodes and depositing material layers for wall formation or for simultaneously cladding two materials in order to form a composite structure. This directed energy deposition-arc (DED-arc) method is advantageous and efficient as it produces large parts with structural integrity due to the high deposition rates, reduced wastage of raw material, and low consumption of energy in comparison with the conventional joining processes and other additive manufacturing technologies. These features have resulted in a constant and continuous increase in interest in this modern manufacturing technique which demands further studies to promote new industrial applications. The high demand for WAAM in aerospace, automobile, nuclear, moulds, and dies industries demonstrates compatibility and reflects comprehensiveness. This paper presents a comprehensive review on the evolution, development, and state of the art of WAAM for non-ferrous materials. Key research observations and inferences from the literature reports regarding the WAAM applications, methods employed, process parameter control, optimization and process limitations, as well as mechanical and metallurgical behavior of materials have been analyzed and synthetically discussed in this paper. Information concerning constraints and enhancements of the wire arc additive manufacturing processes to be considered in terms of wider industrial applicability is also presented in the last part of this paper.

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Metel, Alexander S., Tatiana Tarasova, Andrey Skorobogatov, Pavel Podrabinnik, Yury Melnik, and Sergey N. Grigoriev. "Feasibility of Production of Multimaterial Metal Objects by Laser-Directed Energy Deposition." Metals 12, no. 10 (September 21, 2022): 1566. http://dx.doi.org/10.3390/met12101566.

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The article focuses on the possibility of manufacturing bimetallic products for specific industrial applications using laser-directed energy deposition (LDED) additive technology to replace the traditional brazing process. Preferential process regimes were determined by parametric analysis for the nickel-alloy–steel and molybdenum–steel pairs. Comparative studies of the microstructure and hardness of the deposited layers and the transition layer at the boundary of the alloyed materials have been carried out. It is shown that LDED provides better transition layer and operational properties of the final part since the low-melting copper layer is no longer needed. A combined technological process has been developed, which consists in combining the traditional method of manufacturing a workpiece through the casting and deposition of a molybdenum layer by LDED.

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Reutzel, Edward W., and Abdalla R. Nassar. "A survey of sensing and control systems for machine and process monitoring of directed-energy, metal-based additive manufacturing." Rapid Prototyping Journal 21, no. 2 (March 16, 2015): 159–67. http://dx.doi.org/10.1108/rpj-12-2014-0177.

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Purpose – The purpose of this paper is to surveys classic and recently developed strategies for quality monitoring and real-time control of laser-based, directed-energy deposition.Additive manufacturing of metal parts is a complex undertaking. During deposition, many of the process variables that contribute to overall build quality – such as travel speed, feedstock flow pattern, energy distribution, gas pressure, etc. – are subject to perturbations from systematic fluctuations and random external disturbances. Design/methodology/approach – Sensing and control of laser-based, directed-energy metal deposition is presented as an evolution of methods developed for welding and cladding processes. Methods are categorized as sensing and control of machine variables and sensing and control of build attributes. Within both categories, classic methods are presented and followed by a survey of novel developments. Findings – Additive manufacturing would not be possible without highly automated, computer-based controllers for processing and motion. Its widespread adoption for metal components in critical applications will not occur without additional developments and integration of machine- and process-based sensing systems to enable documentation, and control of build characteristics and quality. Ongoing work in sensing and control brings us closer to this goal. Originality/value – This work serves to introduce researchers new to the field of additive manufacturing to common sources of process defects during metal powder-based, directed-energy deposition processing, and surveys sensing and control methods being investigated to improve the process. The work also serves to highlight, and stress the significance of novel developments in the field.

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Chen, Yunhui, Samuel J. Clark, Lorna Sinclair, Chu Lun Alex Leung, Sebastian Marussi, Thomas Connolley, Robert C. Atwood, et al. "Synchrotron X-ray imaging of directed energy deposition additive manufacturing of titanium alloy Ti-6242." Additive Manufacturing 41 (May 2021): 101969. http://dx.doi.org/10.1016/j.addma.2021.101969.

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