TY - JOUR
T1 - Energy density comparison via highspeed, in-situ imaging of directed energy deposition
AU - Webster, Samantha
AU - Ehmann, Kornel
AU - Cao, Jian
N1 - Funding Information:
The authors would like to acknowledge Tao Sun, Niranjan Parab, and Sarah oW lff for all their support at APS , as well as Yi Shi, Nicolas Martinez , Marisa Bisram, and Shuheng Liao for experiment execution. This research used resources of the Advanced Photon Source, a U.S. Department of Energy (DOE) Office of Science User Facility operated for the DOE Office of Science by Argonne National Laboratory under Contr act No. DE-AC02-06CH 1357. This material is based upon work supported by the National Science Foundation Graduate esearR ch Fellowship under Grant No. DGE -1842165. This research was also funded by NIMSI and CHiMaD .
PY - 2020
Y1 - 2020
N2 - Metal additive manufacturing has become an increasingly popular technology and receives interest from multiple business sectors that require optimally lightweight components and mass customization (aerospace, automotive, and medical device). Directed energy deposition (DED) is one of the main laser-based additive manufacturing processes, but a fundamental understanding of the process is lacking partly because it has not been the focus of highspeed, in-situ x-ray imaging studies like laser powder bed fusion has. A novel in-situ DED system is presented here, and an experimental study is performed to show that the small-scale system recovers processing parameter trends of a full-scale build. Observed meltpool lengths range from about 200 µm to 900 µm, while meltpool depths range from about 50 µm to 500 µm and can support high-fidelity modelling. Additionally, an investigation on the relationship between meltpool dimensions and global energy density GGEEDD' is performed. It was found that GGEEDD' is not a good predictor of meltpool dimensions due to the discrepancy in linear and exponential trends in laser powder and powder mass flowrate. Further studies and analysis using the presented novel DED system are needed to develop an appropriate energy density term to predict of meltpool dimension and clad height.
AB - Metal additive manufacturing has become an increasingly popular technology and receives interest from multiple business sectors that require optimally lightweight components and mass customization (aerospace, automotive, and medical device). Directed energy deposition (DED) is one of the main laser-based additive manufacturing processes, but a fundamental understanding of the process is lacking partly because it has not been the focus of highspeed, in-situ x-ray imaging studies like laser powder bed fusion has. A novel in-situ DED system is presented here, and an experimental study is performed to show that the small-scale system recovers processing parameter trends of a full-scale build. Observed meltpool lengths range from about 200 µm to 900 µm, while meltpool depths range from about 50 µm to 500 µm and can support high-fidelity modelling. Additionally, an investigation on the relationship between meltpool dimensions and global energy density GGEEDD' is performed. It was found that GGEEDD' is not a good predictor of meltpool dimensions due to the discrepancy in linear and exponential trends in laser powder and powder mass flowrate. Further studies and analysis using the presented novel DED system are needed to develop an appropriate energy density term to predict of meltpool dimension and clad height.
KW - Directed energy deposition
KW - Energy density
KW - In-situ x-ray imaging
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U2 - 10.1016/j.promfg.2020.05.101
DO - 10.1016/j.promfg.2020.05.101
M3 - Conference article
AN - SCOPUS:85094875458
VL - 48
SP - 691
EP - 696
JO - Procedia Manufacturing
JF - Procedia Manufacturing
SN - 2351-9789
T2 - 48th SME North American Manufacturing Research Conference, NAMRC 48
Y2 - 22 June 2020 through 26 June 2020
ER -