Skip to main content
SpringerLink
Log in

Surface based variable thickness slicing modeling for laser metal deposition

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Laser metal deposition (LMD) has been a promising additive manufacturing technology widely used in mold rapid manufacturing. In order to improve the capacity of LMD for complex curved surface structures, a surface based variable thickness slicing (S-VTS) model is proposed to adaptively generate the LMD process based on the geometric characteristics of structures. Two deposition strategies in scanning and overlapping directions are designed to enable variable thickness of each cladding layer by dynamically adjusting the scanning speed and overlapping rate. To improve the surface quality and forming efficiency, the discrete particle swarm optimization (DPSO) algorithm is adopt to optimize the process parameters of S-VTS model, including the number of cladding layer, scanning pass, and segment per pass. Several experiments are conducted to form the cuboid samples with wavy and freeform surface and verify the feasibility of the S-VTS model. The results demonstrate that under the open-loop control condition, the geometric accuracy, surface quality, and efficiency of the proposed method is improved in comparison with uniform thickness slicing (UTS) deposition. Moreover, heterogeneous microstructure is always generated by the S-VTS method in terms of grain size and growth direction.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18

Similar content being viewed by others

References

  1. Santos EC, Shiomi M, Osakada K, Laoui T (2006) Rapid manufacturing of metal components by laser forming. Int J Mach Tools Manuf 46(12–13):1459–1468

    Article  Google Scholar 

  2. Lewandowski JJ, Seifi M (2016) Metal additive manufacturing: a review of mechanical properties. Annu Rev Mater Res 46:151–186

    Article  Google Scholar 

  3. Chen L, Chung MF, Tian Y, Joneja A, Tang K (2019) Variable-depth curved layer fused deposition modeling of thin-shells. Robot Comput Integr Manuf 57:422–434

    Article  Google Scholar 

  4. McCaw JC, Cuan-Urquizo E (2018) Curved-layered additive manufacturing of non-planar, parametric lattice structures. Mater Des 160:949–963

    Article  Google Scholar 

  5. Kumar M, Roy Choudhury A (2002) Adaptive slicing with cubic patch approximation. Rapid Prototyp J 8(4):224–232

    Article  Google Scholar 

  6. Huang B, Singamneni S (2015) A mixed-layer approach combining both flat and curved layer slicing for fused deposition modelling. Proc Inst Mech Eng B J Eng Manuf 229(12):2238–2249

    Article  Google Scholar 

  7. Shi T, Lu B, Shi S, Meng W, Fu G (2017) Laser metal deposition with spatial variable orientation based on hollow-laser beam with internal powder feeding technology. Opt Laser Technol 88:234–241

    Article  Google Scholar 

  8. Fathi A, Khajepour A, Durali M, Toyserkani E (2008) Geometry control of the deposited layer in a nonplanar laser cladding process using a variable structure controller. J Manuf Sci Eng 130(3):031003

  9. Ruan J, Tang L, Liou FW, Landers RG (2010) Direct three-dimensional layer metal deposition. J Manuf Sci Eng 132(6):064502

    Article  Google Scholar 

  10. Pi G, Zhang A, Zhu G, Li D, Lu B (2011) Research on the forming process of three-dimensional metal parts fabricated by laser direct metal forming. Int J Adv Manuf Technol 57(9–12):841–847

    Article  Google Scholar 

  11. Ansari M, Razavi RS, Barekat M (2016) An empirical-statistical model for coaxial laser cladding of NiCrAlY powder on Inconel 738 superalloy. Opt Laser Technol 86:136–144

    Article  Google Scholar 

  12. Chen C, Lian G, Jiang J, Wang Q (2018) Simplification and experimental investigation of geometrical surface smoothness model for multi-track laser cladding processes. J Manuf Process 36:621–628

    Article  Google Scholar 

  13. Cao Y, Zhu S, Liang X, Wang W (2011) Overlapping model of beads and curve fitting of bead section for rapid manufacturing by robotic MAG welding process. Robot Comput Integr Manuf 27(3):641–645

    Article  Google Scholar 

  14. Ding D, Pan Z, Cuiuri D, Li H (2015) A multi-bead overlapping model for robotic wire and arc additive manufacturing (WAAM). Robot Comput Integr Manuf 31:101–110

    Article  Google Scholar 

  15. Nickel AH, Barnett DM, Prinz FB (2001) Thermal stresses and deposition patterns in layered manufacturing. Mater Sci Eng A 317(1–2):59–64

    Article  Google Scholar 

  16. Yu J, Lin X, Ma L, Wang J, Fu X, Chen J, Huang W (2011) Influence of laser deposition patterns on part distortion, interior quality and mechanical properties by laser solid forming (LSF). Mater Sci Eng A 528(3):1094–1104

    Article  Google Scholar 

  17. Zhang K, Wang S, Liu W, Shang X (2014) Characterization of stainless steel parts by laser metal deposition shaping. Mater Des 55:104–119

    Article  Google Scholar 

  18. Bax B, Rajput R, Kellet R, Reisacher M (2018) Systematic evaluation of process parameter maps for laser cladding and directed energy deposition. Addit Manuf 21:487–494

    Article  Google Scholar 

  19. Ding D, Pan Z, Cuiuri D, Li H (2015) Wire-feed additive manufacturing of metal components: technologies, developments and future interests. Int J Adv Manuf Technol 81(1–4):465–481

    Article  Google Scholar 

  20. Gu DD, Meiners W, Wissenbach K, Poprawe R (2012) Laser additive manufacturing of metallic components: materials, processes and mechanisms. Int Mater Rev 57(3):133–164

    Article  Google Scholar 

  21. Frazier WE (2014) Metal additive manufacturing: a review. J Mater Eng Perform 23(6):1917–1928

    Article  Google Scholar 

  22. Li W, Soshi M (2019) Modeling analysis of the effect of laser transverse speed on grain morphology during directed energy deposition process. Int J Adv Manuf Technol 103:3279–3291

    Article  Google Scholar 

  23. Farshidianfar MH, Khajepour A, Gerlich AP (2016) Effect of real-time cooling rate on microstructure in laser additive manufacturing. J Mater Process Technol 231:468–478

    Article  Google Scholar 

  24. Guo P, Zou B, Huang C, Gao H (2017) Study on microstructure, mechanical properties and machinability of efficiently additive manufactured AISI 316L stainless steel by high-power direct laser deposition. J Mater Process Technol 240:12–22

    Article  Google Scholar 

  25. Liu W, Wei H, Huang C, Yuan F, Zhang Y (2019) Energy efficiency evaluation of metal laser direct deposition based on process characteristics and empirical modeling. Int J Adv Manuf Technol 102(1–4):901–913

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. School of Mechanical Engineering and Automation, Northeastern University, Shenyang, 110819, China

    Bo Xin, Xianxin Zhou & Yadong Gong

Authors
  1. Bo Xin
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Xianxin Zhou
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Yadong Gong
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Bo Xin.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Xin, B., Zhou, X. & Gong, Y. Surface based variable thickness slicing modeling for laser metal deposition. Int J Adv Manuf Technol 107, 463–474 (2020). https://doi.org/10.1007/s00170-020-05023-4

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-020-05023-4

Keywords

Search

Navigation