A novel model for directed energy deposition-arc based on in-order stacking of primitives

Abstract

ABSTRACT To address the issue of low accuracy of directed energy deposition-arc (DED-Arc) and expand its use in producing large-sized components, a novel concept called “in-order stacking of primitives” has been proposed. This concept aims to simplify the additive manufacturing (AM) planning process and improve forming accuracy. Experiments at the weld, layer, and block levels examined relationships between process parameters and primitive dimensions, offset distance, and interlayer lift height. Increasing heat and mass transfer significantly increased primitive width and surface roughness but had little effect on height variation (1.95-2.27 mm). The impact of offset distance on the forming precision for layer-level components varied by the stacking path used, with Zig-Zig level parts showing more deterioration than Zig-Zag level parts. Thermal equilibrium in block components was achieved within a critical height range of 88.2 to 112.0 mm. The stacking path has a substantial impact on the surface temperature and is a crucial factor for ensure accurate workpiece formation. This study establishes a physical relationship between component forming quality and process parameters through mathematical expressions that are supported by experimental results. Future research will focus on optimizing the physical model and refining the mathematical expressions.