Abstract
In this study, a manufacturing strategy, and guidelines for inclined and multilayered structures of variable thickness are presented, which are based on the results of an own-developed geometrical model that obtains both the coating thickness and dilution. This model is developed for the powder-fed directed energy deposition process (DED) and it only uses the DED single-track cladding characteristics (height, width, area, and dilution depth), the overlap percentage, and the laser head tilting-angle as inputs. As outputs, it calculates both the cladding geometry and the dilution area of the coating. This model for the Ni-based alloy 718 was improved, based on previous studies of the single clad working both vertically and at an inclined angle, adding the equations of the single clad characteristics with respect to the main process parameters. The strategy proposed in this paper for multilayered cladding consisted of both adding an extra clad at the edges of the layer and using a variable value of the overlap percentage between clads for geometric adaptations. With this strategy, the material deposition is more accurate than otherwise, and it shows stable growth. Manufacturing a multilayered wall of wider thicknesses at higher heights was utilized to validate the strategy.
Highlights
Additive manufacturing (AM) is a technology that allows for the manufacturing of three-dimensional complex structures by adding material layer-by-layer
Powder-fed directed energy deposition (DED) technology, known as laser metal deposition (LMD) or laser cladding [3], is an AM process that directs a laser beam at a metallic substrate to produce a melt pool where material is injected in powder form
The trajectory program added one clad to the coating when the overlap percentage was lower than 40%
Summary
Additive manufacturing (AM) is a technology that allows for the manufacturing of three-dimensional complex structures by adding material layer-by-layer. Under the term AM, different manufacturing methods can be distinguished, such as: directed energy deposition (DED), selective laser melting (SLM), binder Jetting, metal jetting, sheet lamination, photo-polymerization, and extrusion, as reported by Mehrpouya et al [1]. Each of these processes is used to deposit different types of materials that are based on the energy source. Powder-fed directed energy deposition (DED) technology, known as laser metal deposition (LMD) or laser cladding [3], is an AM process that directs a laser beam at a metallic substrate to produce a melt pool where material is injected in powder form. The powder mass flow is fused, and a high-quality metallurgical bond solidifies between the substrate and the added material
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