Multilayer Deposition Research Articles

Study on heat transfer and flow of molten pool during the deposition process of laser wire additive manufacturing

In the laser wire additive manufacturing process, the molten pool acts as the critical link between the wire and the deposited part. The heat transfer and flow behavior within the molten pool predominantly determine the quality of the final deposition. Under laser power ranging from 2400 to 3000 W, traverse speeds between 0.01 and 0.04 m/s, and wire feeding speeds from 0.03 to 0.08 m/s, three distinct flow states—single-swirl, double-swirl, and no-swirl—were observed with increasing heat input. Under the optimum process parameters, the molten pool with stable temperature distribution and orderly flow was obtained. In multilayer deposition, the implementation of a laser decay strategy mitigates steep temperature gradients, diminishes the Marangoni effect within the molten pool, and effectively reduces both heat accumulation and lateral flow. Consequently, the flow mode transitions from no-swirl to swirl, and the maximum flow velocity decreases by 40%.

Electrophoretic deposition of novel antibacterial and biocompatible polydopamine and ZIF-8 hybrid composite coating on anodized Ti-6Al-4V alloy with silane primary substrate

Production of biocompatible and corrosion resistance dental implant is a requirement in the modern dental science. In this work, the Ti-6Al-4V was used alloy for the dental implant application that has investigated to make it more corrosion resistive and antibacterial with electrophoretic deposition of silane precursor solution that made of acidic solution of tetraethyl orthosilicate (TEOS) and methyl three ethoxy silane (MTES). The optimized silane coating has been achieved with 30 V, 30 min and at 100 °C ramped annealing by comparison of Taffel analysis and electrochemical impedance spectroscopy (EIS). Also, a new nanocomposite including polydopamine (PDA) and zeolite imidazole frame work composed from Zn (NO3)2 .6H2O and 2-methylimidazole (ZIF-8) that name PDA@ZIF-8 has been used as biocompatible and corrosion resistance amplifier to the precursor solution and used in the multilayer deposition process. The morphology analysis including atomic force microscopy (AFM) and field emission scanning electron microscopy (FESEM) imaging and the obtained parameters show that coating has appropriate roughness that could increase the bounding of implant. A good adhesion strength has been determined for the two-layers silane coating with PDA@ZIF-8 according to the pull- off test. On the other hand, the antibacterial analysis indicate that the coating is an effective material for S. mutans and E. coli reduction that is another criterion for the dental implant materials. The results was introduced the coated Ti-6Al-4V could be used as corrosion resistive and antibacterial dental implant material.

An Investigation of Thermomechanical Behavior in Laser Hot Wire Directed Energy Deposition of NAB: Finite Element Analysis and Experimental Validation

Laser Hot Wire (LHW) Directed Energy Deposition (DED) Additive Manufacturing (AM) processes are capable of manufacturing parts with a high deposition rate. There is a growing research interest in replacing large cast Nickel Aluminum Bronze (NAB) components using LHW DED processes for maritime applications. Understanding thermomechanical behavior during LHW DED of NAB is a critical step towards the production of high-quality NAB parts with desired performance and properties. In this paper, finite element simulations are first used to predict the thermomechanical time histories during LHW DED of NAB test coupons with an increasing geometric complexity, including single-layer and multilayer depositions. Simulation results are experimentally validated through in situ measurements of temperatures at multiple locations in the substrate as well as displacement at the free end of the substrate during and immediately following the deposition process. The results in this paper demonstrate that the finite element predictions have good agreement with the experimental measurements of both temperature and distortion history. The maximum prediction error for temperature is 5% for single-layer samples and 6% for multilayer samples, while the distortion prediction error is about 12% for single-layer samples and less than 4% for multilayer samples. In addition, this study shows the effectiveness of including a stress relaxation temperature at 500 °C during FE modeling to allow for better prediction of the low cross-layer accumulation of distortion in multilayer deposition of NAB.

The effect of productive and quality deposition strategies on residual stress for Directed Energy Deposition (DED) process

In the Directed Energy Deposition (DED) realm, challenges persist concerning process stability and mechanical properties in as-built components. Facts like inconsistent laser head feed rate and accumulated heat during multi-layer deposition result in variations in melt pool energy, causing variant clad widths and heights. Moreover, significant residual stress in as-built DED parts can induce excessive distortions and cracking. To tackle these challenges, offline energy control systems that adjust laser power or feed rate have been implemented to manage melt pool energy and improve productivity. Additionally, an innovative online clad height compensation system has been developed to achieve global height geometry, further boosting productivity. However, the impact of these productive and quality control systems on the mechanical properties of austenitic stainless-steel parts, specifically residual stress, remains unexplored. In this research, residual stress measurements in as-built DED thin wall parts fabricated with energy and/or height control strategies using neutron diffraction have been investigated. The control of three key DED parameters influencing residual stress distribution and magnitude has been identified and discussed. Measurements indicate that neither offline energy control nor online height control adversely affects the quality of the thin wall parts and offline LP-based energy control can reduce residual stress magnitude and its variation. Additionally, the height control results in compressive residual stress with elevated magnitudes. Furthermore, aggressive DED parameters hold the potential for further improvement by pairing with an energy control strategy. This study establishes a foundation for further developing comprehensive control strategies designed to enhance the productivity and quality of DED systems.

Computational modeling of multi-track multi-layer laser directed energy deposition process

This study presents the development of a 3D fully coupled thermomechanical finite element model to evaluate the melt pool geometry, defects, and micro-hardness of multi-track multi-layer deposition in the powder feed laser-directed energy deposition (LDED) technique. Fabrication strategies can significantly affect the melt pool geometry and material behavior of the manufactured components. Understanding the effect of process parameters in a multi-track multi-layer LDED is important. Optimal process parameters are crucial for achieving high-quality deposition in terms of deposition geometry and integrity. The model can aid in mitigating issues such as inadequate inter-track or track-substrate fusion, porosity, cracks, and other defects. A multi-track multi-layer finite element model (FEM) can realistically predict melt pool evolution, mechanical properties, and defects in laser-LDED. This work focuses on the development of a fully coupled thermomechanical model for multi-track multi-layer deposition processes using ABAQUS®. The finite element framework employs Johnson-Cook’s flow stress model for constitutive behavior and the Koistein-Marburger equation for predicting hardness. Two tracks and two layers of SS316L powder are deposited on an SS304 substrate in finite element simulations and experiments. The model has been validated for the melt-pool depth in the substrate, deposition geometry, heat-affected zone, and hardness. It has been observed that there is a ∼10 % error in the prediction of melt pool geometry characterization and a ∼12 % error in hardness as compared to experimental results. The melt-pool width, depth, substrate dilution, and hardness have been characterized as a function of process parameters via simulations and experiments. The model is capable of predicting inter-track and interface defects. In addition, the effect of interlayer cooling on the melt-pool geometry and hardness has been studied.

Feasibility study of using friction stir extruded recycled aluminum rods for welding and additive manufacturing

Friction stir extrusion (FSE) is a promising process capable of producing rods by recycling aluminum chips without melting them. This work studied the use of these recycled rods for GTAW deposition and additive manufacturing. The rods are suitable for single-bead depositions or applications with reduced use of filler material. For additive manufacturing multilayer depositions, the component presented a density of 77% (23% porosity), so pollutant sources must be further reduced to improve quality. The work shows that porosity significantly changes along the height, being about 10% close to the substrate, and about 45% next to the upper surface.

Characterization of Ni-Cu multilayers deposition on low carbon steel substrate using electroplating technique

Abstract Low carbon steel is widely used in oil and gas applications. In this research, multilayers of Nickel (Ni) and Copper (Cu) were deposited on a low carbon steel substrate using the electroplating process (ELP). Initially, a layer of Ni was coated, followed by a layer of Cu. ELP was implemented using water bath containing (300 g/l) of NiSO4.6H2O, (30 g/l) of (NiCl2.6H2O), (40 g/l) of H3BO3 and (30 g/l) of (NaCN), (30 g/l) of (CuCN), (10 g/l) of (NaOH.6H2O). First bath parameters were temperature is (59 - 60 °C), current density in the range of (3-5 A/dcm2), voltage was holed at (8 V) for Ni, and temperature was between (50-51 °C), current density in the range of (1-2 A/dcm2), voltage was holed at (4 V), while the plating time (10 minutes) for both Ni and Cu. The results refer to Ni, Cu, and Ni & Cu ELP thicknesses 3, 4.77 and 6.75 μm respectively. Metallurgical tests were achieve including the micro hardness of ELP, Vickers micro hardness results showed improvement in hardness values compared, with steel substrate, and in the presence of Ni, Cu, Ni+Cu layers, 322, 581, 479, and 562 Hv respectively. The roughness was measured using surface roughness measurement device. The average surface roughness (Ra) depicted satisfying values as a result of Ni layer coating, which gave uniform surface distribution with Ra 0.363 μm. X-ray diffraction (XRD) test examinations serve as strong evidence for the presence of Ni and Cu in the internal and external finish layers, respectively. Corrosion examinations were carried out in seawater solution (3.5 g NaCl) the corrosion behavior tends to be more resistance, with layers of Ni, and Cu in sea water environment, which is considered an important criterion to increase the part life.

Effects of Magnetostatic Interactions in FeNi-Based Multilayered Magnetoimpedance Elements.

Multilayered [Cu(3 nm)/FeNi(100 nm)]5/Cu(150 nm)/FeNi(10 nm)/Cu(150 nm)/FeNi(10 nm)/Cu(150 nm)/[Cu(3 nm)/FeNi(100 nm)]5 structures were obtained by using the magnetron sputtering technique in the external in-plane magnetic field. From these, multilayer magnetoimpedance elements were fabricated in the shape of elongated stripes using the lift-off lithographic process. In order to obtain maximum magnetoimpedance (MI) sensitivity with respect to the external magnetic field, the short side of the rectangular element was oriented along the direction of the technological magnetic field applied during the multilayered structure deposition. MI sensitivity was defined as the change of the total impedance or its real part per unit of the magnetic field. The design of the elements (multilayered structure, shape of the element, etc.) contributed to the dynamic and static magnetic properties. The magnetostatic properties of the MI elements, including analysis of the magnetic domain structure, indicated the crucial importance of magnetostatic interactions between FeNi magnetic layers in the analyzed [Cu(3 nm)/FeNi(100 nm)]5 multilayers. In addition, the uniformity of the magnetic parameters was defined by the advanced technique of the local measurements of the ferromagnetic resonance field. Dynamic methods allowed investigation of the elements at different thicknesses by varying the frequency of the electromagnetic excitation. The maximum sensitivity of 40%/Oe with respect to the applied field in the range of the fields of 3 Oe to 5 Oe is promising for different applications.

Active and passive infrared emittance tuning using optically transparent unpatterned ITO thin films

Tailoring of thermal emittance has applications in smart radiators, camouflage, infrared (IR) scene generation, stealth, and thermal management. Various studies have explored avenues to achieve both passive and active emittance tuning using methods such as meta-surfaces, phase change materials, composites, nanostructure arrays and multi-layer stacks. Most of these methods often involve complex fabrication processes like multilayer depositions and micro/nano patterning, limiting their scalability for large-scale applications. This study presents a straightforward and scalable approach for passive and active emittance tuning using Indium Tin Oxide (ITO) films deposited on a high emissivity flexible polyethylene terephthalate (PET) substrate. By changing the deposition time, the thickness of the ITO film is controlled which changes the observed emissivity of the ITO/PET composite structure over a wide range (0.2–0.94) while maintaining optical transparency. Using this approach for passive emittance tuning, we demonstrate an IR scene generation application. As the ITO film is conducting, by applying voltage to the ITO/PET sheet, its temperature is changed using which active emittance tuning is also achieved. Compared to existing methods of emittance tuning, the presented approach is simpler, gives flexible films with optical transparency, and has the potential for large-scale integration, enabling cost-effective and scalable manufacturing of emittance-tuned surfaces.

Elucidating the effects of metal transfer modes and investigating the material properties in wire-arc additive manufacturing (WAAM)

AbstractStudies have shown the influence of WAAM process parameters on mechanical properties, bead formation, dimensional accuracy, and microstructure. However, metal transfer modes and their interactions with input variables have not been investigated thoroughly. Therefore, short/spray, pulse and double pulse modes were investigated in this study at different current levels. Bead-on-plate trials were conducted by depositing ER70S-6 wire to investigate bead morphology, dilution, microstructure, and hardness. The study was supported by a detailed statistical approach, including analysis of variance (ANOVA) and regression analysis. Similarly, the combined effects of hatch distance and current were studied on bead formation in multi-layer deposits. Moreover, a thin wall and a cubic structure were deposited to realize the WAAM capability for larger depositions. The microstructures of thin wall and cubic structure were analyzed using optical microscopy (OM) and scanning electron microscopy (SEM). The study concludes that metal transfer modes at various currents significantly influence bead geometry, microstructure and hardness. The microstructure of bead-on-plate trials show fine lamellar structure at low current in all modes. Higher current results in coarse grains with a polygonal and columnar morphology. The hardness shows a decreasing trend as the current increases. The combined effects of current and hatch distance alter bead morphology; however, an optimized combination yields smoother surfaces. The microstructure of thin wall showed a slight anisotropy along the building direction. The presence of small pores was witnessed from OM and SEM images. Similarly, the cubic structure showed a more homogeneous microstructure with much lower porosity. The hardness profile of the thin wall exhibited small fluctuations along the building direction, while that of the cubic structure was more uniform.

Enhanced Photocatalytic Properties and Photoinduced Crystallization of TiO2-Fe2O3 Inverse Opals Fabricated by Atomic Layer Deposition.

The use of solar energy for photocatalysis holds great potential for sustainable pollution reduction. Titanium dioxide (TiO2) is a benchmark material, effective under ultraviolet light but limited in visible light utilization, restricting its application in solar-driven photocatalysis. Previous studies have shown that semiconductor heterojunctions and nanostructuring can broaden the TiO2's photocatalytic spectral range. Semiconductor heterojunctions are interfaces formed between two different semiconductor materials that can be engineered. Especially, type II heterojunctions facilitate charge separation, and they can be obtained by combining TiO2 with, for example, iron(III) oxide (Fe2O3). Nanostructuring in the form of 3D inverse opals (IOs) demonstrated increased TiO2 light absorption efficiency of the material, by tailoring light-matter interactions through their photonic crystal structure and specifically their photonic stopband, which can give rise to a slow photon effect. Such effect is hypothesized to enhance the generation of free charges. This work focuses on the above-described effects simultaneously, through the synthesis of TiO2-Fe2O3 IOs via multilayer atomic layer deposition (ALD) and the characterization of their photocatalytic activities. Our results reveal that the complete functionalization of TiO2 IOs with Fe2O3 increases the photocatalytic activity through the slow photon effect and semiconductor heterojunction formation. We systematically explore the influence of Fe2O3 thickness on photocatalytic performance, and a maximum photocatalytic rate constant of 1.38 ± 0.09 h-1 is observed for a 252 nm template TiO2-Fe2O3 bilayer IO consisting of 16 nm TiO2 and 2 nm Fe2O3. Further tailoring the performance by overcoating with additional TiO2 layers enhances photoinduced crystallization and tunes photocatalytic properties. These findings highlight the potential of TiO2-Fe2O3 IOs for efficient water pollutant removal and the importance of precise nanostructuring and heterojunction engineering in advancing photocatalytic technologies.

Additive manufacturing nickel-aluminum bronze alloy via wire-fed electron beam directed energy deposition: Enhanced mechanical properties and corrosion resistance compared to as-cast counterpart

In the present work, a wall-structured nickel-aluminum bronze (NAB) alloy was fabricated via electron beam directed energy deposition (EB-DED) additive manufacturing with a single-pass multi-layer deposition strategy. A comprehensive comparative analysis of microstructure, mechanical properties, and corrosion resistance was conducted against a conventionally cast NAB alloy. The inherent rapid solidification and cyclic thermal processing of the EB-DED technique profoundly influenced the microstructural evolution of the NAB alloy. The as-deposited NAB alloy exhibited a fine-grained microstructure, devoid of the martensitic β′ phase, accompanied by the spheroidization of partial κIII precipitates, and a homogeneous distribution of alloying elements. These distinctive microstructural attributes synergistically enhanced the strength, hardness, and toughness of the NAB alloy, conferring superior mechanical properties compared to its cast counterpart. Furthermore, the as-deposited alloy demonstrated remarkable corrosion resistance in a 3.5 wt% NaCl solution, significantly outperforming the cast alloy. The underlying mechanisms governing the structure-property relationships were elucidated. This comprehensive investigation provided insights into the unique characteristics and potential applications of EB-DED fabricated NAB alloys, positioning them as promising candidates for high-performance components subjected to severe mechanical and corrosive service conditions.

Tunable Nanoislands Decorated Tapered Optical Fibers Reveal Concurrent Contributions in Through-Fiber SERS Detection.

Creating plasmonic nanoparticles on a tapered optical fiber (TF) tip enables a remote surface-enhanced Raman scattering (SERS) sensing probe, ideal for challenging sampling scenarios like biological tissues, site-specific cells, on-site environmental monitoring, and deep brain structures. However, nanoparticle patterns fabricated from current bottom-up methods are mostly random, making geometry control difficult. Uneven statistical distribution, clustering, and multilayer deposition introduce uncertainty in correlating device performance with morphology. Ultimately, this limits the design of the best-performance remote SERS sensing probe. Here we employ a tunable solid-state dewetting method to create densely packed monolayer Au nanoislands with varied geometric parameters in direct contact with the silica TF surface. These patterns exhibit analyzable nanoparticle sizes, densities, and uniform distribution across the entire taper surface, enabling a systematic investigation of particle size, density, and analyte effects on the SERS performance of the through-fiber detection system. The study is focused on the SERS response of a widely employed benchmark molecule, rhodamine 6G (R6G), and serotonin, a highly relevant neurotransmitter for the neuroscience field. The numerical simulations and limit of detection (LOD) experiments on R6G show that the increase of the total near-field enhancement volume promotes the SERS sensitivity of the probe. However, we observed a different behavior for serotonin linked to its interaction with the nanoparticle's surface. The obtained LOD is as low as 10-7 M, a value not achieved so far in a through-fiber detection scheme. Therefore, our work offers a strategy to design nanoparticle-based remote SERS sensing probes and provides new clues to discover and understand intricate plasmonic-driven chemical reactions.

Gold nano densities: Relationship with drying parameters

Gold nanorod stain deposits have been studied using helium ion microscopy (HIM). The multilayer thick deposits can become well-organized monolayers when the density drops, as demonstrated by the density fluctuation of nanosuspension. However, once the density of nanoparticles approaches certain extremely low values, this tendency has disappeared. The difference in density associated with the liquid crystalline (LC) phases that have developed on the surface. There is a correlation between the density of nanoparticles in suspension and the relationship between droplet volume and UV-Vis absorbance. The physical characteristics that affect and generate such LC phases are contrasted and examined with the assembly method. To highlight noteworthy aspects, a quantitative comparison between the HIM analysis and the SEM is also made. Analyzing the correlation between the coffee stain range, nanoparticle density, and droplet contact angle is essential. It is possible to quantify the difference in the ring stains from the outside to the midle and from the midle to the inner boundary. HIM is typically useful when attempting to determine the true composition of surface deposits. The aim of this work is to investigate the effects of particle density on liquid crystalline superstructures and the coffee stain effect.

Laser Deposition of Metal Halide Perovskites.

Vacuum-based or vapor-phase deposition is the most mature and widely used method for thin-film growth in the semiconductor industry. Yet, the vapor-phase growth of halide perovskites remains relatively underexplored compared to solution process deposition. The intrinsically largely distinct volatilities of organic and inorganic components in halide perovskites challenge the standard physical vapor deposition techniques. Thermal coevaporation tackles this with independent thermally controlled sources per precursor. Alternatively, pulsed laser deposition uses the energy of a laser to eject material from a target via thermal and nonthermal processes. This provides high versatility in the target composition, enabling the deposition of complex (including hybrid) thin films from a single-source target. This Perspective presents an overview of recent advances in laser-based deposition of halide perovskites, discusses advantages and challenges, and motivates the development of physical vapor deposition methods for hybrid materials, especially for applications requiring dry, conformal, and multilayer deposition.

Development of an advanced in-line multilayer deposition system at Diamond Light Source.

A state-of-the-art multilayer deposition system with a 4200 mm-long linear substrate translator housed within an ultra-high vacuum chamber has been developed. This instrument is engineered to produce single and multilayer coatings, accommodating mirrors up to 2000 mm in length through the utilization of eight rectangular cathodes. To ensure the quality and reliability of the coatings, the system incorporates various diagnostic tools for in situ thickness uniformity and stress measurement. Furthermore, the system features an annealing process capable of heating up to 700°C within the load-lock chamber. The entire operation, including pump down, deposition and venting processes, is automated through user-friendly software. In addition, all essential log data, power of sputtering source, working pressure and motion positions are automatically stored for comprehensive data analysis. Preliminary commissioning results demonstrate excellent lateral film thickness uniformity, achieving 0.26% along the translation direction over 1500 mm in dynamic mode. The multilayer deposition system is poised for use in fabricating periodic, lateral-graded and depth-graded multilayers, specifically catering to the beamlines for diverse scientific applications at Diamond Light Source.

Solid-state friction rolling repair technology for various forms of defects through multi-layer multi-pass deposition

The current Friction Stir Welding (FSW) based solid-state defect repairing method is an ideal repair technology for high-strength aluminum alloy. However, due to the limitation of pin length and the existence of shoulder, the stirring pin cannot penetrate deep into the root of defects and is difficult to extend in the width direction, which poses great challenges for components with large defects, such as one-dimensional, two-dimensional and volume defects. To overcome these limitations, this study successfully achieved effective repair of various forms of defects using the solid-state Friction Rolling Repair (FRR) technology through multi-layer multi-bead deposition. The microstructure and mechanical properties of the repaired ZL114A cast aluminum alloy joints were investigated. The results demonstrate well-bonded repaired boundaries, significant grain refinement at the junction between the repaired area and boundary, and ultimate tensile strength exceeding 80 % of base material strength. The average grain size of the repaired area can reach a minimum of 2.82 μm. The grain refinement degree of the side joint of the surface defect repair sample is higher than that of the bottom joint, and the corner joint of the bottom surface shows the highest proportion of recrystallized grains. Fracture locations were consistently within the interior of the repair zone in tensile specimens, indicating superior properties at side joints compared to those within the interior. The research proves that FRR has the ability to repair a variety of typical defects, including one-dimensional, two-dimensional and volume defects, in the process of processing and service, which lays a foundation for the industrial application of FRR.

Experimental study and parameter optimization of laser wire additive manufacturing of titanium alloy

In the single-pass multilayer deposition process of laser wire additive manufacturing, variations in process parameters significantly influence the morphology of the deposited layer. This study experimentally investigates how the main process parameters (laser power, scanning speed, and wire feeding speed) affect the morphology of the deposited layer. It was found that each parameter has distinct effects on the geometrical morphology of deposition. Simultaneously, aiming to enhance the surface topography of the deposited layer and its bonding with the substrate, three optimization objectives are defined. An optimization model is then constructed using experimental data to refine the process parameters. The optimal parameters are determined through experimentation, resulting in significant enhancement of the deposited layer’s topography.

A comprehensive transformation-thermomechanical model on deformation history in directed energy deposition of high-speed steel

ABSTRACT Phase transformation is a crucial factor that determines the quality and deformation of components in laser-directed energy deposition (L-DED). Owing to the limitations of in situ observation methods, there is a lack of effective means to study the complete phase transformation and their impacts on deformation during the deposition process. In this study, multilayer heterogeneous deposition was investigated with the high-carbon high-speed steel by modelling the coupled phase transformation-thermomechanical physics. The methodology was proposed to identify the specific phase transformations by iteratively comparing the whole deformation history between digital image correlation (DIC) measurements and simulations. Besides the thermo-mechanical coupling effect and basic volumetric phase transformation, carbon partitioning between precipitated carbides and matrix was manifested, which also resulted in a rise of the Ms point by 208.4 °C and a reduction of the transformation rate by 73.2%. Additionally, an increase of 13.8% in energy absorption could be attributed to the surface oxidation of the deposited layer. The model predictions exhibited good consistency with the DIC in-situ measurement data, indicating that the deformation history contained sufficient information on the phase transformations. Based on the proposed transformation-thermomechanical coupling model, it helps to understand the complete phase transformation during deposition.

Integrating data-driven system to predict temperature and distortion in multi-layer direct metal deposition processes

This study proposed a framework to train an artificial neural network (ANN) by a data-driven system to predict the temperature and distortion in multi-layer direct metal deposition (DMD) of SS 304. By integrating thermomechanical variables, the research ensures the fidelity of finite element (FE) simulations, which are validated against existing data. Notably, the study achieves enhanced precision over prior work by varying the heat input sources and heat transfer equations. A novel aspect of this research is the use verified FE simulation to add data to data-driven system to train an efficient ANN for predicting temperature and distortion based on key parameters such as laser power and scanning speed. The iterative process involved multiple FE simulations with varying laser parameters to refine the ANN’s predictive capabilities. This methodology enabled the identification of relationships between manufacturing parameters, temperature, and distortion. The iterative training continued until the ANN’s predictions and subsequent FE simulation results converged within an acceptable margin. The findings confirm that the trained ANN can predict temperature and distortion both accurately and expediently, marking a significant advancement in the control of the DMD process.Graphical