Repairing Automotive Dies With Directed Energy Deposition: Industrial Application and Life Cycle Analysis

2018 ◽  
Vol 141 (2) ◽  
Author(s):  
Jennifer Bennett ◽  
Daniel Garcia ◽  
Marie Kendrick ◽  
Travis Hartman ◽  
Gregory Hyatt ◽  
...  
Keyword(s):  
Life Cycle ◽  
Environmental Impacts ◽  
Energy Deposition ◽  
Repair Process ◽  
Directed Energy Deposition ◽  
Die Life ◽  
Hybrid Repair ◽  
Directed Energy ◽  
Number Of Cycles ◽  
Manufacturing Technologies

Powder-based additive manufacturing technologies are developing rapidly. To assess their applicability, comparison of performance and environmental impacts between additive technologies and conventional techniques must be performed. Toyota manufactures over two million aluminum four-cylinder engines in the U.S. each year via die casting. The dies used in this process are traditionally repaired via tungsten inert gas (TIG) welding and only last an average of 20.8% of the number of cycles of the original die life before another repair is needed. A hybrid repair process involving machining away the damaged areas and then rebuilding them additively via powder-blown directed energy deposition (DED) has been developed. The die repaired via DED resulted in the same life as the original die. The use of DED repair eliminated the need for emergency repairs and nonscheduled downtime on the line because the DED repaired dies last for as many cycles as the original die before another repair is needed. Life cycle analyses were conducted comparing the traditional welding repair process to the DED repair process. The results show that the DED repair process results in significantly less damage to the assessed impact categories except for ionizing radiation. Therefore, it can be concluded that the DED repair process could lessen most environmental impacts compared to traditional welding repair. Further work toward increasing energy and material efficiencies of the method could yield further reductions in environmental impacts.

scholarly journals Experimental and Numerical Investigation in Directed Energy Deposition for Component Repair

Materials ◽  
2021 ◽  
Vol 14 (6) ◽  
pp. 1409
Author(s):  
Lan Li ◽  
Xinchang Zhang ◽  
Frank Liou
Keyword(s):  
Mechanical Properties ◽  
Energy Deposition ◽  
Surface Defects ◽  
Repair Process ◽  
Field Analysis ◽  
Element Analysis ◽  
Mechanical Field ◽  
Directed Energy Deposition ◽  
Considerable Impact ◽  
Directed Energy

Directed energy deposition (DED) has been widely used for component repair. In the repair process, the surface defects are machined to a groove or slot and then refilled. The sidewall inclination angle of the groove geometry has been recognized to have a considerable impact on the mechanical properties of repaired parts. The objective of this work was to investigate the feasibility of repairing various V-shaped defects with both experiments and modeling. At first, the repair volume was defined by scanning the defective zone. Then, the repair volume was sliced to generate the repair toolpath. After that, the DED process was used to deposit Ti6Al4V powder on the damaged plates with two different slot geometries. Mechanical properties of the repaired parts were evaluated by microstructure analysis and tensile test. Testing of the repaired parts showed excellent bonding between the deposits and base materials with the triangular slot repair. 3D finite element analysis (FEA) models based on sequentially coupled thermo-mechanical field analysis were developed to simulate the corresponding repair process. Thermal histories of the substrate on the repair sample were measured to calibrate the 3D coupled thermo-mechanical model. The temperature measurements showed very good verification with the predicted temperature results. After that, the validated model was used to predict the residual stresses and distortions in the parts. Predicted deformation and stress results can guide the evaluation of the repair quality.

scholarly journals A Hybrid Modeling of the Physics-Driven Evolution of Material Addition and Track Generation in Laser Powder Directed Energy Deposition

Materials ◽  
2019 ◽  
Vol 12 (17) ◽  
pp. 2819 ◽  
Author(s):  
Gabriele Piscopo ◽  
Eleonora Atzeni ◽  
Alessandro Salmi
Keyword(s):  
Experimental Data ◽  
Process Parameters ◽  
Energy Deposition ◽  
Complex Task ◽  
Melt Pool ◽  
Directed Energy Deposition ◽  
Proposed Model ◽  
Directed Energy ◽  
Manufacturing Technologies ◽  
Analytic Models

Directed Energy Deposition (DED) is one of the most promising additive manufacturing technologies for the production of large metal components and because of the possibility it offers of adding material to an existing part. Nevertheless, DED is considered premature for industrial production, because the identification of the process parameters may be a very complex task. An original hybrid analytic-numerical model, related to the physics of laser powder DED, is presented in this work in order to evaluate easily and quickly the effects of different sets of process parameters on track deposition outcomes. In the proposed model, the volume of the deposited material is modeled as a function of process parameters using a synergistic interaction between regression-based analytic models and a novel element activation strategy. The model is implemented in a Finite Element (FE) software, and the forecasting capability is assessed by comparing the numerical results with experimental data from the literature. The predicted results show a reasonable correlation with the experimental dimensions of the melt pool and demonstrate that the proposed model may be used for prediction purposes, if a specific set of process parameters that guarantees adequate adhesion of the deposited track to the substrate is introduced.

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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