Directed Energy Deposition (DED) has emerged as a promising metal additive manufacturing technique due to its ability to create components comparable or superior to traditional fabrication. Although industrial adoption of this technology is underway, there exists a considerable need to improve the predictability of the components it manufactures to promote wider adoption of this technology. Currently, melt pool temperature is the primary metric for build monitoring and control. However, stronger correlations must be established between the process parameters, including melt pool temperature, and resulting material outcomes to determine if melt pool control is a sufficient metric to control part quality. The goal of this research is to establish correlations between laser power (W), scanning speed (mm/s), powder flow rate (g/min), average melt pool temperature (C), and hardness. The average melt pool temperature was measured through Photodiode-based Planck thermometry (PDPT) with dual on-axis photodiodes. To obtain the correlation between these factors, 54 samples of Inconel 718 were printed, cross-sectioned, and tested using a Vickers diamond indenter. The resulting correlations exhibited extremely low R2 values and validated the findings of previous studies in that process parameters are exceedingly poor predictors of component properties. Average melt pool temperature lacked a significant correlation with hardness, instead process scanning speed demonstrated a more significant impact on the final material hardness. Since hardness is largely dictated by average grain size which in turn is controlled primarily by solidification rate, solidification rate should be the focus of future work to control material properties. The results of this study indicate that melt pool thermal control is not a sufficient metric to control part quality, and a solution is needed that can oversee the build process in such a way that solidification rate can be monitored and controlled in addition or instead of melt pool temperature. Future work must be done to apply the PDPT methodology to real time calibrated indirect measurement of melt pool solidification rates to improve prediction and control of final part mechanical properties.
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