Abstract
A dynamic powder splitting system (DPSS) was developed to overcome a slow powder flow rate (PFR) response in conventional powder delivery systems used in the Directed Energy Deposition (DED) additive manufacturing process. Complementary to the main powder delivery system, the DPSS uses a custom valve to split powder flow and cyclone separator to redirect powder flow that is not used in the cladding process. Its potential applications are compensation for clad height inconsistencies caused by machine feed rate errors and increase of powder usage efficiency via a powder recycling system. Various tests were performed to verify performance and cladding.
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