Abstract
Multi-Faceted Monitoring of Powder Flow Rate Variability in Directed Energy Deposition
Highlights
Directed Energy Deposition (DED) systems use nozzles to focus a mixed stream of metal powder and gas into the melt pool, making it one of the more critical components affecting build quality[1,2]
The primary focus was the frequency of hopper turntable rotation, which is the characteristic of this hopper design most likely to introduce variation
The hopper was loaded with approximately 3 kg of GA316 powder and >200 g of powder was run through the pipework to allow the system to stabilise before collecting data
Summary
Directed Energy Deposition (DED) systems use nozzles to focus a mixed stream of metal powder and gas into the melt pool, making it one of the more critical components affecting build quality[1,2]. Studies have considered how the nozzle design influences the shape of the powder cone, using a range of measurement and modelling techniques to determine the shape and position of the powder focal point compared with the laser focal point[1,2,8]. These have included analysis using line lasers and high speed cameras to understand the shape of the powder flow distribution[9,10,11], which has led to a commercially available system developed by Fraunhofer IWS[12]. These studies have considered snapshot behaviour from a single image exposure rather than how the flow rate and shape of powder distribution varies over time
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