Thin wall deposition of IN625 using directed energy deposition

2020 ◽  
Vol 56 ◽  
pp. 1366-1373 ◽  
Author(s):  
Myong Joon Kim ◽  
Christopher Saldana
Keyword(s):  
Energy Deposition ◽  
Thin Wall ◽  
Wall Deposition ◽  
Directed Energy Deposition ◽  
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.

scholarly journals An Extended Lumped-Parameter Model of Melt–Pool Geometry to Predict Part Height for Directed Energy Deposition

2017 ◽  
Vol 139 (9) ◽  
Author(s):  
Jianyi Li ◽  
Qian Wang ◽  
Panagiotis (Pan) Michaleris ◽  
Edward W. Reutzel ◽  
Abdalla R. Nassar
Keyword(s):  
Energy Deposition ◽  
Temperature Fields ◽  
Temperature History ◽  
Extended Model ◽  
Thin Wall ◽  
Melt Pool ◽  
Directed Energy Deposition ◽  
Lumped Parameter ◽  
Single Bead ◽  
Directed Energy

There is a need for the development of lumped-parameter models that can be used for real-time control design and optimization for laser-based additive manufacturing (AM) processes. Our prior work developed a physics-based multivariable model for melt–pool geometry and temperature dynamics in a single-bead deposition for a directed energy deposition process and then validated the model using experimental data from deposition of single-bead Ti–6AL–4V (or Inconel®718) tracks on an Optomec® Laser Engineering Net Shaping (LENS™) system. In this paper, we extend such model for melt–pool geometry in a single-bead deposition to a multibead multilayer deposition and then use the extended model on melt–pool height dynamics to predict part height of a three-dimensional build. Specifically, the extended model incorporates temperature history during the build process, which is approximated by super-positioning the temperature fields generated from Rosenthal's solution of point heat sources, with one heat source corresponding to one bead built before. The proposed model for part height prediction is then validated using builds with a variety of shapes, including single-bead thin wall structures, a patch build, and L-shaped structures, all built with Ti–6AL–4V using an Optomec® LENSTM MR-7 system. The model predictions on average part height show reasonable agreement with the measured average part height, with error rate less than 15%.

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.

Development of thick SiC coating on thin wall tube of zircaloy-4 using laser based directed energy deposition technique

2020 ◽  
Vol 398 ◽  
pp. 126088
Author(s):  
Arun Kumar Rai ◽  
B. Srinivasulu ◽  
Christ Prakash Paul ◽  
Rashmi Singh ◽  
Sanjay Kumar Rai ◽  
...  
Keyword(s):  
Energy Deposition ◽  
Thin Wall ◽  
Deposition Technique ◽  
Directed Energy Deposition ◽  
Directed Energy

scholarly journals Ti6Al4V Thin Walls Production using Laser Directed Energy Deposition (L-DED) Process

2021 ◽  
Vol 6 (3) ◽  
pp. 124-131
Author(s):  
German Barragan ◽  
Fabio Mariani ◽  
Reginaldo Coelho
Keyword(s):  
Energy Deposition ◽  
Wear Test ◽  
Hardness Test ◽  
Thin Wall ◽  
Primary Role ◽  
Thin Walls ◽  
Directed Energy Deposition ◽  
Wall Structures ◽  
Component Shape ◽  
Directed Energy

One of the main applications of Directed Energy Deposition (DED) is the production of thin-wall structures, where it has significant advantages over traditional milling and machining techniques, or even welded analogues. These kinds of structures are frequently employed in aerospace components, field where titanium alloys have a primary role to play. Amongst them, the most employed is the Ti6Al4V with an alpha + beta alloy containing 6% Aluminium (Al) and 4% Vanadium (V). It has an excellent combination of strength and toughness along with excellent corrosion resistance. For the study hereby, thin-wall structures were constructed employing a Laser Directed Energy Deposition machine (L-DED), working with powder material. Analyse identified some microstructural and mechanical characteristics, thorough metallographic study, wear test (micro-adhesive) and micro hardness test. Finding a grain refined structure with competitive mechanical properties compared to materials manufactured by traditional processes. Results positioning DED as an attractive manufacturing technology, with a huge potential to improve costs and material usage, besides almost no restriction on component shape.

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