Abstract
Directed Energy Deposition Additive Manufacturing (DED-AM) is one of the principal AM techniques being explored for both the repair of high value components in the aerospace industry as well as freeform fabrication of large metallic components. However, the lack of fundamental understanding of the underlying process-structure-property relationships hinders the utilisation of DED-AM for the production or repair of safety-critical components. This study uses in situ and operando synchrotron X-ray imaging to provide an improved fundamental understanding of laser-matter interactions and their influence on the melt pool geometry. Coupled with process modelling, these unique observations illustrate how process parameters can influence the DED-AM melt pool geometry. The calibrated simulation can be used for guidance in an industrial additive manufacturing process for microstructure and quality control.
Highlights
Directed Energy Deposition Additive Manufacturing (DED-AM) [1] is one of the most promising subsets of Laser Additive Manufacturing (LAM) and is considered a key technique for both the repair [2] of existing components [3] as well as freeform fabrication [4]
This study uses in situ and operando synchrotron X-ray imaging to provide an improved fundamental understanding of laser-matter interactions and their influence on the melt pool geometry
The results present in this work enable an enhanced understanding of DED-AM processes and facilitate improved manufacturing practice
Summary
Directed Energy Deposition Additive Manufacturing (DED-AM) [1] is one of the most promising subsets of Laser Additive Manufacturing (LAM) and is considered a key technique for both the repair [2] of existing components [3] as well as freeform fabrication [4]. The lack of fundamental understanding of the underlying process-structure-property relationships hinders the utilisation of DEDAM for safety-critical components such as turbine aerofoil repair [2]. The ability to predict and control microstructure during the laser deposition process holds the key to realising a high-quality product. The thermal gradient at the solidification interface is a crucial parameter for controlling the final microstructure [5] and is directly related to the process parameters (e.g. laser power, spot size, traverse speed, etc). The reliance upon ex situ characterisation of the final microstructure [1, 6, 7] and mechanical properties [8,9,10,11] of DED-AM deposits is an inefficient and costly means of process optimisation. It is unable to elucidate the mitigations to the aforementioned restraints on DED-AM utilisation
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