High-speed direct energy deposition as a high-throughput design tool for laser-based additive manufacturing

IF 4.2 Q2 ENGINEERING, MANUFACTURING
Klaus Büßenschütt , Patrick Köhnen , Fabian Kies , Stephan Koß , Johannes Henrich Schleifenbaum , Christian Haase
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引用次数: 0

Abstract

A wide range of additive manufacturing (AM) processing conditions can be rapidly realized within a single specimen via high-speed direct energy deposition laser based (DED-LB), due to a variety of cooling conditions and in-situ powder mixing. Since existing approaches are inefficient in exploring the vast material and process design space in AM, high-speed DED-LB can be employed as a novel technology for high-throughput alloy design tool. However, an evaluation of the process transferability of the high-speed DED-LB process with respect to the currently dominating metal AM technologies, namely laser powder bed fusion (PBF LB/M) and conventional DED-LB, is required. In this study, high-speed DED-LB is applied for the high-throughput sample production, using the nickel alloy IN718 as reference material as well as the AM processes PBF LB/M and DED-LB as reference processes. The resulting microstructures are characterized and compared using optical microscopy and large-area scanning electron microscopy (SEM) analysis combined with energy-dispersive X-ray spectroscopy (EDS). Furthermore, a model for calculation of the volumetric energy density is developed to compare the applied AM processes. The significant influence of the processing conditions on the solidification behavior of the investigated material allows for efficient exploration of the microstructure and phase composition. Specific high-speed DED-LB-process conditions achieved the average solidification cell size and laves phase content as observed in the PBF LB/M- and DED-LB -produced counterparts. The applicability of the high-speed DED-LB process for rapid alloy and process development, i.e., process transferability, is critically evaluated. The results show that high-speed DED-LB can be used to emulate cooling conditions of PBF-LB/M and DED-LB and, therefore, be used as tool for rapid alloy development.

高速直接能量沉积作为激光增材制造的高通量设计工具
由于各种冷却条件和原位粉末混合,通过基于高速直接能量沉积激光(d - lb)的快速增材制造(AM)加工条件可以在单个样品内快速实现。由于现有方法在探索AM中广阔的材料和工艺设计空间方面效率低下,高速d - lb可以作为一种高通量合金设计工具的新技术。然而,对于目前主导的金属增材制造技术,即激光粉末床熔融(PBF LB/M)和传统的d -LB,需要对高速d -LB工艺的工艺可移植性进行评估。本研究以镍合金IN718为参比材料,采用增材制造工艺PBF LB/M和d -LB为参比工艺,采用高速d -LB进行高通量样品生产。利用光学显微镜和大面积扫描电镜(SEM)结合能量色散x射线能谱分析(EDS)对所得的微观结构进行了表征和比较。此外,还建立了计算体积能量密度的模型,以比较应用的增材制造工艺。加工条件对所研究材料凝固行为的显著影响使得对微观组织和相组成的有效探索成为可能。在特定的高速d -LB工艺条件下,PBF LB/M-和d -LB生产的同类产品的凝固细胞尺寸和叶片相含量达到了平均水平。高速d - lb工艺对快速合金和工艺开发的适用性(即工艺可转移性)进行了严格评估。结果表明,高速d - lb可以模拟PBF-LB/M和d - lb的冷却条件,可以作为快速开发合金的工具。
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
Additive manufacturing letters
Additive manufacturing letters Materials Science (General), Industrial and Manufacturing Engineering, Mechanics of Materials
CiteScore
3.70
自引率
0.00%
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0
审稿时长
37 days
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