Energy and mass assessment of the laser Directed Energy Deposition process (DED-LB) for reduced environmental impact

Abstract

ABSTRACT Additive Manufacturing (AM) processes have the capability to promote a more rational use of resources, reduce generated waste, as well as repair damaged components to extend their lifespan. With the aim of contributing to a more efficient and environmentally friendlier manufacturing process, this research work investigates the energy consumption of the Laser Directed Energy Deposition process (DED-LB) through the introduction of new parameters in its characterisation, which are energy and mass efficiency. First, the energy efficiency of the laser generator itself has been characterised. Based on the results obtained, it was possible to conclude that pulsed laser operation strategies allow a reduction in consumption of up to 9% compared to a continuous laser operation mode. Second, a design of experiments was carried out to relate the energy and mass efficiency of the deposition process to the input parameters: laser power, feed rate, and mass rate. The parameter that most influences the energy efficiency of the process is the mass rate, where high rates are advisable to maximise its value. On the other hand, it is concluded that an increase in the mass rate or a reduction in the feed rate results in an increase in the mass efficiency