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Effect of laser energy density on bead characteristics in wire-DED

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Abstract

Achieving repeatability in part production remains a challenge in laser-wire feed directed energy deposition (LW-DED). It is necessary to understand the laser-wire deposition and bead aspect ratio varying the process conditions to achieve repeatability. Laser energy density is one of the key process parameters that affect the dimensions of the deposit. So, this study discusses the fundamentals of depositing the copper-coated ER70S-6 low carbon steel wire. The laser energy density effects on aspect ratio, overall porosity, microstructure, and microhardness are presented. The bead morphology changes with the change in laser energy density. Single track deposited sample results helped in understanding the melt transition for material deposition and dimensional resolution of the deposited track.

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Abbreviations

\(\rho_{sample}\) :

Density of deposited track (g/cm3)

\(\rho_{fluid}\) :

Density of fluid (g/cm3)

\(\rho_{air}\) :

Density of air (g/cm3)

\(M_{air}\) :

Mass of sample in air (g)

\(M_{fluid}\) :

Mass of sample in fluid (g)

Sp1:

Spot 1

AM:

Additive manufacturing

HAZ:

Heat affected zone

LW-DED:

Laser-wire feed directed energy deposition

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Acknowledgements

The laser system used for this study was established through grant received from the Department of Science and Technology (DST), Governement of India under Project Number DST/TDT/AMT/2017/026.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Indian Institute of Technology Ropar, Rupnagar, Punjab, 140001, India

    Sumitkumar Rathor, Ravi Kant & Ekta Singla

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  1. Sumitkumar Rathor
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  2. Ravi Kant
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Correspondence to Ravi Kant.

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Rathor, S., Kant, R. & Singla, E. Effect of laser energy density on bead characteristics in wire-DED. Sādhanā 49, 104 (2024). https://doi.org/10.1007/s12046-024-02472-5

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