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Effect of Abnormal Powder Feeding on Mechanical Properties of Fabricated Part in Directed Energy Deposition

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Abstract

Directed energy deposition (DED) is widely employed in the automotive, aerospace, and defense industries for defect repair and remanufacturing. Stable powder feeding through nozzles for the quality of parts is crucial in the DED process. Detecting changes in the powder flow caused by nozzle defects is visually challenging, and identifying defects in additively manufactured components is equally difficult unless significant distortion occurs. Therefore, prior understanding regarding the quality degradation and development mechanism of process defects associated with abnormal powder feeding is necessary, and product defects must be observed. This research focuses on analyzing the effect of nozzle failure on the shape and mechanical properties of parts. Computational fluid dynamics analysis is performed to examine physical phenomena resulting from an abnormal powder supply. Based on the results, an obstructed nozzle causes an abnormal powder supply, thus resulting in defects in additively manufactured components owing to distortions in the melting-pool flow and temperature distribution.

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Data Availability

The data that support the findings of this study are available on request from the corresponding author.

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Acknowledgements

This study has been conducted with the support of the Korea Institute of Industrial Technology, Republic of Korea (EO230007), Ministry of Trade, Industry and Energy, Republic of Korea (KM230167), and National Research Foundation of Korea (NRF) grant funded by the Korea government (MSIT) (No. 2023R1A2C1007231, and No. 2019R1A5A8083201).

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Authors and Affiliations

  1. Customized Manufacturing R&D Department, Korea Institute of Industrial Technology (KITECH), 113-58 Seohaean-Ro, Siheung, 15014, Republic of Korea

    Jeongho Yang, Seonghun Ji, Du-Rim Eo, Jongcheon Yoon & Hyub Lee

  2. School of Mechanical Engineering, Pusan National University, Busan, 46241, Republic of Korea

    Jeongho Yang & Sang-Hu Park

  3. Department of Mechanical Engineering, Hanyang University, 222 Wangsimni-Ro, Seongdong-Gu, Seoul, 04763, Republic of Korea

    Seonghun Ji

  4. Department of Convergence Manufacturing System Engineering, University of Science and Technology (UST), 217, Gajeong-Ro, Yuseong-Gu, Daejeon, 34113, Republic of Korea

    Hyub Lee

  5. School of Engineering, The University of Waikato, Hamilton, 3240, New Zealand

    Parviz Kahhal

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Contributions

Jeongho Yang: Conceptualization, Methodology, Visualization, Investigation, Formal analysis, Data curation, Software, Writing—original draft, Writing—review & editing. Seonghun Ji: Visualization, Formal analysis, Investigation. Du-Rim Eo: Methodology, Formal analysis, Investigation. Jongcheon Yoon: Methodology, Investigation, Formal analysis. Parviz Kahhal: Methodology, Investigation, Formal analysis, Writing—review & editing. Hyub Lee: Conceptualization, Supervision, Funding acquisition, Project administration, Writing—original draft, Writing—review & editing. Sang-Hu Park: Conceptualization, Supervision, Funding acquisition, Project administration, Writing—original draft, Writing—review & editing.

Corresponding authors

Correspondence to Hyub Lee or Sang-Hu Park.

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Yang, J., Ji, S., Eo, DR. et al. Effect of Abnormal Powder Feeding on Mechanical Properties of Fabricated Part in Directed Energy Deposition. Int. J. of Precis. Eng. and Manuf.-Green Tech. (2024). https://doi.org/10.1007/s40684-024-00620-0

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