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Thermo-mechanical Modelling of the Directed Energy Deposition (DED) Process for the Optimization of Deposition Strategies

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Dynamic Response and Failure of Composite Materials (DRAF 2022)

Part of the book series: Lecture Notes in Mechanical Engineering ((LNME))

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Abstract

Directed Energy Distribution (DED) process involves a continuous and subsequent deposition of layers, by means of a laser heat source that melts the feedstock material supplied in form of powders or wires. Laser power, powder flow rate, travel speed affect temperature gradient distribution and residual stresses in components. Due to this, the main process parameters’ influence on DED process was investigated, followed by a fine-tuning.

The main objective of this work was to compare four simulations with different scanning strategies for the to-be-printed component, focusing on deformation results. To achieve this objective, the 3DExperience software was essential in simulating DED process accurately. Setting up the Finite Element Method (FEM) model, mesh type, material properties, and boundary conditions followed a strict procedure.

As final step, once the best case in terms of deformations from a production perspective has been highlighted, the component is subjected to post-processing machining to respect the designed dimensioning and tolerances.

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Acknowledgement

This work has been partially supported by the award “TESUN-83486178370409 finanziamento dipartimenti di eccellenza CAP. 1694 TIT. 232 ART. 6”, which was conferred by Ministero dell'Istruzione, dell’Università e della Ricerca and by the Interdepartmental Centre for Integrated Additive Manufacturing (IAM@PoliTo) at the Politecnico di Torino, Torino, Italy.

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Authors and Affiliations

  1. Exemplar s.r.l., Corso Vittorio Emanuele II, 161, 10139, Torino, Italy

    Marco Vallone & Massimo Damasio

  2. Department of Management and Production Engineering (DIGEP), Politecnico di Torino, Corso Duca degli Abruzzi, 24, 10129, Torino, Italy

    Eleonora Atzeni, Mirna Poggi & Alessandro Salmi

Authors
  1. Marco Vallone
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  2. Massimo Damasio
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  3. Eleonora Atzeni
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  4. Mirna Poggi
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  5. Alessandro Salmi
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Corresponding author

Correspondence to Marco Vallone .

Editor information

Editors and Affiliations

  1. DICMaPI, University of Naples Federico II, Naples, Italy

    Valentina Lopresto

  2. DICMaPI, University of Naples Federico II, Naples, Italy

    Ilaria Papa

  3. DICMaPI, University of Naples Federico II, Naples, Italy

    Antonio Langella

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Vallone, M., Damasio, M., Atzeni, E., Poggi, M., Salmi, A. (2023). Thermo-mechanical Modelling of the Directed Energy Deposition (DED) Process for the Optimization of Deposition Strategies. In: Lopresto, V., Papa, I., Langella, A. (eds) Dynamic Response and Failure of Composite Materials. DRAF 2022. Lecture Notes in Mechanical Engineering. Springer, Cham. https://doi.org/10.1007/978-3-031-28547-9_23

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  • DOI: https://doi.org/10.1007/978-3-031-28547-9_23

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  • Publisher Name: Springer, Cham

  • Print ISBN: 978-3-031-28546-2

  • Online ISBN: 978-3-031-28547-9

  • eBook Packages: EngineeringEngineering (R0)

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