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Visualization of melt pool stability for wire- and powder-based directed energy deposition repair of gray cast iron

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Abstract

Gray cast iron is favorable in agricultural and automotive castings for its high strength and wear resistance but offers difficulty during remanufacturing. Key challenges include restoring strength while avoiding brittle phases during solidification and porosity generation. While wire-based directed energy deposition (DED) repair studies are limited, powder-based DED has shown promise under specific thermal conditions. Determining these conditions is challenging due to the localized and transient nature of the process. Herein, in situ high-speed imaging is employed for quantifying melt pool stability for optimal thermal conditions in wire- and powder-based DED repair of gray cast iron. The rate of gas generation and escapement from the melt pool is driven by laser power and traverse speed. Stable deposition conditions, i.e., minimal melt pool geometric deviation, are identified for both media types, and the resultant strength is quantified. The insights provided by in situ imaging promote superior parameter selection and are extendable to other difficult-to-repair materials.

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Acknowledgements

The authors would like to thank Dr. David Trauernicht and Dr. Denis Cormier for their assistance with CT scanning. The authors would also like to thank the AMPrint Center for allowing the use of the DED machine and high-speed camera.

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Authors and Affiliations

  1. Department of Industrial and Systems Engineering, Rochester Institute of Technology, One Lomb Memorial Drive, Rochester, NY, 14623, USA

    Jakob D. Hamilton & Iris V. Rivero

  2. Department of Industrial and Manufacturing Systems Engineering, Iowa State University, 2529 Union Drive, Ames, IA, 50011, USA

    Jakob D. Hamilton

  3. Department of Industrial and Systems Engineering, University of Florida, 303 Weil Hall, Gainesville, FL, 32611-6595, USA

    Iris V. Rivero

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Contributions

Both authors contributed to the study conception and design. Material preparation, sample fabrication, imaging, and analysis were performed by Jakob D. Hamilton. Material acquisition, experiment ideation, and oversight were provided by Iris V. Rivero. The first draft of the manuscript was written by Jakob D. Hamilton, and both Iris V. Rivero and Jakob D. Hamilton contributed toward subsequent revisions. Both authors read and approved the final manuscript.

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Correspondence to Iris V. Rivero.

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Hamilton, J.D., Rivero, I.V. Visualization of melt pool stability for wire- and powder-based directed energy deposition repair of gray cast iron. Int J Adv Manuf Technol 129, 4399–4405 (2023). https://doi.org/10.1007/s00170-023-12513-8

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  • DOI: https://doi.org/10.1007/s00170-023-12513-8

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