Investigation of temperature distribution and solidification morphology in multilayered directed energy deposition of Al-0.5Sc-0.5Si alloy

2022 ◽  
Vol 186 ◽  
pp. 122492
Author(s):  
Amit Kumar Singh ◽  
Yasham Mundada ◽  
Priyanshu Bajaj ◽  
Markus B. Wilms ◽  
Jeet P Patil ◽  
...  
Keyword(s):  
Temperature Distribution ◽  
Energy Deposition ◽  
Directed Energy Deposition ◽  
Solidification Morphology ◽  
Directed Energy

THERMAL MONITORING AND MODELING OF TI-6AL-4V THIN WALL TEMPERATURE DISTRIBUTION DURING BLOWN POWDER LASER DIRECTED ENERGY DEPOSITION

2021 ◽  
pp. 1-19
Author(s):  
Basil Paudel ◽  
Garrett Marshall ◽  
Scott M. Thompson
Keyword(s):  
Steady State ◽  
Temperature Distribution ◽  
Energy Deposition ◽  
Thermal Capacity ◽  
Thin Wall ◽  
Thin Walled Structures ◽  
Melt Pool ◽  
Directed Energy Deposition ◽  
Directed Energy ◽  
Blown Powder

Abstract The effects of Ti-6Al-4V part size on its temperature distribution during the blown-powder directed energy deposition (DED) process was investigated through dual-thermographic monitoring and a unique modeling technique. Results demonstrate that the duration of dwell times presented to be a significant contributing factor affecting the rate at which a steady-state temperature field is achieved. As a result, the longer wall took significantly more layers/time to achieve a uniform temperature profile within the wall. Maximum and average melt pool temperatures appear to be near independent of part size at a steady state. Finite element simulation results showed that a quasi-steady melt pool temperature may be unique to a layer, especially during earlier cladding process near the substrate and that the layer-wise steady melt pool was achieved within the first few seconds of track scanning. A proposed fin modeling-based temperature distribution was found to predict the thermal profile in a ‘substrate affected zone’ (SAZ) along the scan direction within 5%. A method to predict the onset of the SAZ has also been proposed. Process parameters used for the DED of component volumes are not necessarily optimal for thin-walled structures due to significantly less thermal capacity.

Thermal Monitoring and Modeling of Ti-6Al-4V Thin Wall Temperature Distribution During Blown Powder Laser Directed Energy Deposition

2021 ◽  
Author(s):  
Basil J. Paudel ◽  
Garrett J. Marshall ◽  
Scott M. Thompson
Keyword(s):  
Steady State ◽  
Temperature Distribution ◽  
Energy Deposition ◽  
Thermal Capacity ◽  
Thin Wall ◽  
Thin Walled Structures ◽  
Melt Pool ◽  
Directed Energy Deposition ◽  
Directed Energy ◽  
Blown Powder

Abstract The effects of Ti-6Al-4V part size on its temperature distribution during the blown-powder directed energy deposition-laser (DED-L) process was investigated through dual-thermographic monitoring and a unique modeling technique. Results demonstrate that the duration of dwell times are a significant contributing factor affecting the rate at which a steady-state temperature field is achieved. Longer walls took significantly more layers/time to achieve a uniform temperature profile. Maximum and average melt pool temperatures appear to be near independent of part size at a steady state. Finite element simulation results show that a quasi-steady melt pool temperature may be unique to a layer, especially for layers near the substrate. Layer-wise steady melt pool temperatures were achieved within the first few seconds of track scanning. A proposed fin modeling-based temperature distribution was found to predict the thermal profile in a ‘substrate affected zone’ (SAZ) along the scan direction within 5%. A method to predict the onset of the SAZ has also been proposed. Process parameters used for the DED-L of component volumes are not necessarily optimal for thin-walled structures due to their significantly lower thermal capacity.

scholarly journals Correction to: Characterization and Optimization of Process Parameters for Directed Energy Deposition Powder-Fed Laser System

2021 ◽  
Author(s):  
Daniel Andres Rojas Perilla ◽  
Johan Grass Nuñez ◽  
German Alberto Barragan De Los Rios ◽  
Fabio Edson Mariani ◽  
Reginaldo Teixeira Coelho
Keyword(s):  
Process Parameters ◽  
Energy Deposition ◽  
Laser System ◽  
Directed Energy Deposition ◽  
Optimization Of Process Parameters ◽  
Directed Energy

scholarly journals Hot-Wire Laser-Directed Energy Deposition: Process Characteristics and Benefits of Resistive Pre-Heating of the Feedstock Wire

Metals ◽  
2021 ◽  
Vol 11 (4) ◽  
pp. 634
Author(s):  
Agnieszka Kisielewicz ◽  
Karthikeyan Thalavai Pandian ◽  
Daniel Sthen ◽  
Petter Hagqvist ◽  
Maria Asuncion Valiente Bermejo ◽  
...  
Keyword(s):  
Heat Input ◽  
Energy Deposition ◽  
Fine Tuning ◽  
Hot Wire ◽  
Process Stability ◽  
Electrical Signals ◽  
Melt Pool ◽  
Directed Energy Deposition ◽  
Directed Energy ◽  
The Stability

This study investigates the influence of resistive pre-heating of the feedstock wire (here called hot-wire) on the stability of laser-directed energy deposition of Duplex stainless steel. Data acquired online during depositions as well as metallographic investigations revealed the process characteristic and its stability window. The online data, such as electrical signals in the pre-heating circuit and images captured from side-view of the process interaction zone gave insight on the metal transfer between the molten wire and the melt pool. The results show that the characteristics of the process, like laser-wire and wire-melt pool interaction, vary depending on the level of the wire pre-heating. In addition, application of two independent energy sources, laser beam and electrical power, allows fine-tuning of the heat input and increases penetration depth, with little influence on the height and width of the beads. This allows for better process stability as well as elimination of lack of fusion defects. Electrical signals measured in the hot-wire circuit indicate the process stability such that the resistive pre-heating can be used for in-process monitoring. The conclusion is that the resistive pre-heating gives additional means for controlling the stability and the heat input of the laser-directed energy deposition.

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