Abstract
The laser melt deposition process often involves fabricating custom alloys from cost-effective elemental powder blends. However, discrepancies between the nominal ratio of the pre-mixed powders and the final composition of the deposited part are commonly observed due to variations in the material properties of the elemental powders. In this study, separate experiments were employed to investigate the relationship of deposition characteristics between individual elemental powders and elemental powder blends in the laser melt deposition process. To investigate the spatial distribution between elemental powder particles, powder flow characteristics in four different delivery systems were measured. Single-track deposition experiments were deployed to study the real powder catchment efficiency of elemental powder and the final composition of the deposited layer. In addition, a finite element model was established and validated with experimental data to predict the dilution rate and final chemical composition of the deposited layer. The experimental results indicate a strong correlation between the powder catchment efficiency of individual elemental powder and the final composition of the deposited layer. The simulation results agreed well with the actual composition of the deposited track. This study’s findings have the potential to predict and optimize the composition of the desired materials fabricated by elemental powder blends in the laser melt deposition process.
Published Version
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