A Multi-Axis Slicing Method for Direct Laser Deposition Process

2010 ◽  
Author(s):  
Divya Kanakanala ◽  
Swathi Routhu ◽  
Jianzhong Ruan ◽  
Xiaoqing Frank Liu ◽  
Frank Liou
Keyword(s):  
Deposition Process ◽  
Metal Deposition ◽  
Laser Deposition ◽  
Deposition Technique ◽  
Metal Part ◽  
Topological Information ◽  
Direct Laser Deposition ◽  
Layer Deposition ◽  
Direct Laser ◽  
Slicing Method

With multi-axis capability, direct laser deposition process can produce a metal part without the usage of support structures. In order to fully utilize such a capability, the paper discusses a slicing method for multi-axis metal deposition process. Using the geometry information of adjacent layers, the slicing direction and layer thickness can be changed as needed. A hierarchy structure is designed to manage the topological information which is used to determine the slicing sequence. Its usage is studied to build overhang type structure. With such a character, some overhang features such as holes, can be deposited directly to save the required machining operation and material cost, which improves the efficiency of the metal deposition process. Combined with direct 3D layer deposition technique, the multi-axis slicing method is implemented.

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.

scholarly journals Direct Laser Deposition for Tailored Structure

2021 ◽  
Author(s):  
Alessia Teresa Silvestri ◽  
Sasan Amirabdollahian ◽  
Matteo Perini ◽  
Paolo Bosetti ◽  
Antonino Squillace
Keyword(s):  
Manufacturing Industry ◽  
Industrial Applications ◽  
Laser Deposition ◽  
Innovative Technology ◽  
Metal Part ◽  
Machining Time ◽  
Direct Laser Deposition ◽  
Direct Laser ◽  
New Material

In the context of Industry 4.0, interest is increasing towards Additive Manufacturing processes due to their several advantages. Among these, the Direct Laser Deposition (DLD) is an innovative technology for additive metal part fabrication, and it is currently demonstrating its ability to revolutionize the manufacturing industry. It is particularly interesting for industrial applications in terms of reduction of waste materials by starting with fewer feedstocks, reduction of machining time by only have material where it is needed but, above all, it is interesting to extend the life of parts. Indeed, with the DLD, it is possible to repair an item or coat parts via cladding, making it more wear-resistant. It is also possible to give "another life" to broken or waste components, for example, by replacing the damaged area using new material. Moreover, particularly intriguing is the possibility to create hybrid or graded parts by varying material/alloy concentrations. This paper aims to combine the abovementioned advantages to develop tailored structures in order to accomplish complex and functional products. For this purpose, a specific case study was investigated, starting with the study of the appropriate powders to use and ending with the printing process using the DMG Mori Lasertec65. Microstructural and mechanical analyses were carried out to evaluate the products and to validate the process. The final results show the properties and performances of products obtained using this technology.

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.

Sign in / Sign up

Export Citation Format

Share Document