Effects of Laser-Powder Alignment on Clad Dimension and Melt Pool Temperature in Directed Energy Deposition

IF 2.4 3区 工程技术 Q3 ENGINEERING, MANUFACTURING
Jihoon Jeong, Samantha Webster, Rujing Zha, Jon-Erik Mogonye, Kornel Ehmann, Jian Cao
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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.
定向能沉积中激光粉末对熔覆层尺寸和熔池温度的影响
摘要定向能沉积(DED)的工艺参数包括激光功率、粉末流速和扫描速度等,得到了广泛的研究。这些参数影响着包层尺寸和熔池温度,直接关系到零件质量。然而,由于表征过程繁琐,激光/粉末轮廓及其对准得到的关注较少,尽管它们可以直接与熔池形成的局部能量密度相关。本文研究了激光对线和粉末流分布对熔覆层尺寸和熔池温度的影响。激光束和粉末轮廓的特征是通过测量它们各自的二维高斯轮廓在给定的距离。然后使用对齐和不对齐的激光粉末轮廓来构建单层方形几何形状。结果表明,激光中心和粉末轮廓之间的500µm偏移会导致单包层的宽度和高度变化20%,平均温度升高100 K。为了了解粉末流动、能量通量和局部温度之间的相互作用,我们绘制了二维的局部比能量密度分布图。这些结果表明,激光粉末错位可能会显著改变沉积覆层的热历史和形状,可能会阻止ded制造的部件达到设计性能并导致构建失败。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
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来源期刊
CiteScore
6.80
自引率
20.00%
发文量
126
审稿时长
12 months
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
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