Self-Sufficient Modeling of Single Track Deposition of Ti–6Al–4V With the Prediction of Capture Efficiency

2018 ◽  
Vol 141 (1) ◽  
Author(s):  
Christopher Katinas ◽  
Shunyu Liu ◽  
Yung C. Shin
Keyword(s):  
Molten Pool ◽  
Deposition Process ◽  
Capture Efficiency ◽  
Laser Deposition ◽  
Single Track ◽  
Profile Error ◽  
Track Geometry ◽  
Direct Laser Deposition ◽  
Direct Laser ◽  
Traditional Manufacturing

Understanding the capture efficiency of powder during direct laser deposition (DLD) is critical when determining the overall manufacturing costs of additive manufacturing (AM) for comparison to traditional manufacturing methods. By developing a tool to predict the capture efficiency of a particular deposition process, parameter optimization can be achieved without the need to perform a costly and extensive experimental study. The focus of this work is to model the deposition process and acquire the final track geometry and temperature field of a single track deposition of Ti–6Al–4V powder on a Ti–6Al–4V substrate for a four-nozzle powder delivery system during direct laser deposition with a LENS™ system without the need for capture efficiency assumptions by using physical powder flow and laser irradiation profiles to predict capture efficiency. The model was able to predict the track height and width within 2 μm and 31 μm, respectively, or 3.3% error from experimentation. A maximum of 36 μm profile error was observed in the molten pool, and corresponds to errors of 11% and 4% in molten pool depth and width, respectively. Based on experimentation, the capture efficiency of a single track deposition of Ti–6Al–4V was found to be 12.0%, while that from simulation was calculated to be 11.7%, a 2.5% deviation.

scholarly journals Using a Trial Sample on Stainless Steel 316L in a Direct Laser Deposition Process

Metals ◽  
2021 ◽  
Vol 11 (10) ◽  
pp. 1550
Author(s):  
Artur Vildanov ◽  
Konstantin Babkin ◽  
Ruslan Mendagaliyev ◽  
Andrey Arkhipov ◽  
Gleb Turichin
Keyword(s):  
Power Level ◽  
Deposition Process ◽  
Laser Deposition ◽  
Technological Parameters ◽  
Stainless Steel 316L ◽  
Track Width ◽  
Direct Laser Deposition ◽  
Large Size ◽  
Deposition Parameters ◽  
Direct Laser

Direct laser deposition technology is used for the manufacture of large-size products with complex geometries. As a rule, trial samples with small dimensions are made to determine the deposition parameters. In order for the resulting products to have the required performance characteristics, it is necessary to minimize the number of internal macrodefects. Non-fusion between the tracks are defects that depend on the technological mode (power, speed, track width, etc.). In this work, studies have been carried out to determine the power level at which non-fusion is formed, dwell time between the tracks on the model samples. This paper considers the issue of transferring the technological parameters of direct laser deposition from model samples to a large-sized part, and describes the procedure for making model samples.

Finite element modelling of substrate thermal distortion in direct laser additive manufacture of an aero-engine component

2012 ◽  
Vol 227 (9) ◽  
pp. 1987-1999 ◽  
Author(s):  
S Marimuthu ◽  
D Clark ◽  
J Allen ◽  
AM Kamara ◽  
P Mativenga ◽  
...  
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Deposition Process ◽  
Machining Process ◽  
Laser Deposition ◽  
Element Analysis ◽  
Direct Laser Deposition ◽  
Direct Laser ◽  
Engine Component ◽  
Aero Engine

The shape complexity of aerospace components is continuously increasing, which encourages researchers to further refine their manufacturing processes. Among such processes, blown powder direct laser deposition process is becoming an economical and energy efficient alternative to the conventional machining process. However, depending on their magnitudes, the distortion and residual stress generated during direct laser deposition process can affect the performance and geometric tolerances of manufactured components. This article reports an investigation carried out using the finite element analysis method to predict the distortion generated in an aero-engine component produced by the direct laser deposition process. The computation of the temperature induced during the direct laser deposition process and the corresponding distortion on the component was accomplished through a three-dimensional thermo-structural finite element analysis model. The model was validated against measured distortion values of the real component produced by direct laser deposition process using a Trumpf DMD505 CO2 laser. Various direct laser deposition fill patterns (orientation strategies/tool movement) were investigated in order to identify the best parameters that will result in minimum distortion.

Influence of Technological Parameters of Direct Laser Deposition Process on the Structure and Properties of Deposited Products from Alloy Ti-6Al-4V

2018 ◽  
Vol 284 ◽  
pp. 306-311 ◽  
Author(s):  
M.O. Gushchina ◽  
Olga G. Klimova-Korsmik ◽  
Gleb A. Turichin ◽  
S.A. Shalnova
Keyword(s):  
Defect Formation ◽  
Deposition Process ◽  
Laser Deposition ◽  
Aviation Industry ◽  
Aircraft Industry ◽  
Technological Parameters ◽  
Turbine Engine ◽  
Direct Laser Deposition ◽  
Direct Laser ◽  
Engine Components

The technology of direct laser deposition is the most promising for using in various industries. One of the most interesting areas for using this technology is an aviation industry. Due to their unique properties, titanium alloys are widely used in the aircraft industry for gas turbine engine components. In this paper, the effect of DLD process parameters on defect formation and structure is considered. The influence of energy density on the mechanical properties of parts is determined.

Modeling Particle Spray and Capture Efficiency for Direct Laser Deposition Using a Four Nozzle Powder Injection System

2017 ◽  
Author(s):  
Christopher Katinas ◽  
Weixiao Shang ◽  
Yung C. Shin ◽  
Jun Chen
Keyword(s):  
Numerical Model ◽  
Free Stream ◽  
Capture Efficiency ◽  
Laser Deposition ◽  
Injection System ◽  
Powder Injection ◽  
Surface Geometry ◽  
Direct Laser Deposition ◽  
Direct Laser ◽  
Deposition Simulation

Powder capture efficiency is indicative of the amount of material that is added to the substrate during laser additive manufacturing processes, and thus, being able to predict capture efficiency provides capability of predictive modeling during such processes. The focus of the work presented in this paper is to create a numerical model to understand particle trajectories and velocities, which in turn allows for the prediction of capture efficiency. To validate the numerical model, particle tracking velocimetry experiments at two powder flow rates were conducted on free stream particle spray to track individual particles such that particle concentration and velocity fields could be obtained. Results from the free stream comparison showed good agreement to the trends observed in experimental data and were subsequently used in a direct laser deposition simulation to assess capture efficiency and temperature profile at steady-state. The simulation was validated against a single track deposition experiment and showed proper correlation of the free surface geometry, molten pool boundary, heat affected zone boundary and capture efficiency.

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