{"title":"Effects of Laser-Powder Alignment on Clad Dimension and Melt Pool Temperature in Directed Energy Deposition","authors":"Jihoon Jeong, Samantha Webster, Rujing Zha, Jon-Erik Mogonye, Kornel Ehmann, Jian Cao","doi":"10.1115/1.4063390","DOIUrl":null,"url":null,"abstract":"Abstract The process parameters of Directed Energy Deposition (DED) have been widely studied including laser power, powder flow rate, and scanning speed. These parameters affect clad dimension and melt pool temperature, which are directly related to part quality. However, laser/powder profiles and their alignment have obtained less attention due to the cumbersome characterization process, although they can be directly associated with local energy density for melt pool formation. This study examines the impact of the alignment between the laser beam and powder flow distributions in DED on clad dimension and melt pool temperature. The laser beam and powder profiles are characterized by measuring their respective 2D Gaussian profiles for a given standoff distance. Aligned and misaligned laser-powder profiles are then used to build single-clad square geometries. It was found that a 500-µm offset between the centers of the laser and powder profiles causes up to a 20% change in both the width and the height of a single clad as well as an average temperature increase of 100 K. To understand the interaction between powder flow, energy flux, and local temperature, the local specific energy density distribution was plotted in 2D. These results suggest that laser-powder misalignment may significantly alter the thermal history and shape of deposited clads, possibly preventing DED-manufactured parts from meeting design properties and causing build failures.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":null,"pages":null},"PeriodicalIF":2.4000,"publicationDate":"2023-10-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Journal of Manufacturing Science and Engineering-transactions of The Asme","FirstCategoryId":"1085","ListUrlMain":"https://doi.org/10.1115/1.4063390","RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q3","JCRName":"ENGINEERING, MANUFACTURING","Score":null,"Total":0}
引用次数: 0
Abstract
Abstract The process parameters of Directed Energy Deposition (DED) have been widely studied including laser power, powder flow rate, and scanning speed. These parameters affect clad dimension and melt pool temperature, which are directly related to part quality. However, laser/powder profiles and their alignment have obtained less attention due to the cumbersome characterization process, although they can be directly associated with local energy density for melt pool formation. This study examines the impact of the alignment between the laser beam and powder flow distributions in DED on clad dimension and melt pool temperature. The laser beam and powder profiles are characterized by measuring their respective 2D Gaussian profiles for a given standoff distance. Aligned and misaligned laser-powder profiles are then used to build single-clad square geometries. It was found that a 500-µm offset between the centers of the laser and powder profiles causes up to a 20% change in both the width and the height of a single clad as well as an average temperature increase of 100 K. To understand the interaction between powder flow, energy flux, and local temperature, the local specific energy density distribution was plotted in 2D. These results suggest that laser-powder misalignment may significantly alter the thermal history and shape of deposited clads, possibly preventing DED-manufactured parts from meeting design properties and causing build failures.
期刊介绍:
Areas of interest including, but not limited to: Additive manufacturing; Advanced materials and processing; Assembly; Biomedical manufacturing; Bulk deformation processes (e.g., extrusion, forging, wire drawing, etc.); CAD/CAM/CAE; Computer-integrated manufacturing; Control and automation; Cyber-physical systems in manufacturing; Data science-enhanced manufacturing; Design for manufacturing; Electrical and electrochemical machining; Grinding and abrasive processes; Injection molding and other polymer fabrication processes; Inspection and quality control; Laser processes; Machine tool dynamics; Machining processes; Materials handling; Metrology; Micro- and nano-machining and processing; Modeling and simulation; Nontraditional manufacturing processes; Plant engineering and maintenance; Powder processing; Precision and ultra-precision machining; Process engineering; Process planning; Production systems optimization; Rapid prototyping and solid freeform fabrication; Robotics and flexible tooling; Sensing, monitoring, and diagnostics; Sheet and tube metal forming; Sustainable manufacturing; Tribology in manufacturing; Welding and joining