Introduction of the Experimental Setup for the Investigation of the Novel Selective Melt Dispersion (SMD): A Directed Energy Deposition (DED) Process

Abstract

This study focuses on developing an experimental setup to investigate the Selective Melt Dispersion (SMD), a Directed Energy Deposition (DED) process. SMD as a means of in-process joining (IPJ) aims to integrate components and assemblies during additive manufacturing, combining the advantages of various processes for eco-friendly and economical resource utilization. The research initially analyzed DED systems and defined requirements for subsystems and the overall system. Critical subsystems, including the energy source, material feed, and others, were sequentially developed, and a proof of concept involved building 20 stacked welded tracks, validated through micrograph analysis. The study concludes by evaluating and discussing the fulfillment of the defined requirements. The system comprises a centrally arranged vibration-assisted powder feed; a laterally arranged laser incidence at a 45° angle; a kinematic structure where all axes are arranged on the workpiece, so the powder supply does not require movement; and a shield gas supply.