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A study on the effect of directed energy deposition substrate energy on clad geometry

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Abstract

Directed energy deposition (DED) is an additive manufacturing (AM) process where a laser is used to fuse a metal powder onto a substrate. The powder is deposited in a layer-by-layer fashion, and each deposited track is referred to as the clad. Large thermal gradients that occur during DED can cause changes in the clad geometry as well as deformation of the substrate and final part. Thermal behavior of DED manufactured parts and mitigation of thermal distortion has been addressed in the literature, but these studies mainly focused on material properties while neglecting the effect of thermal distortion on part geometry. One of the mitigation strategies that has been widely tested and accepted is substrate preheating. This study uses analytical and experimental models to observe changes in clad geometry when energy input to the part is varied by adjusting process parameters and preheating the substrate. A method to quantify substrate energy, or the amount of heat energy the substrate holds, is found as well as a relationship between the substrate energy and clad geometry. The geometry of the clad can be controlled by controlling the total energy added to the clad.

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Acknowledgments

The authors would like to thank DMG Mori and MTTRF for their support of the ARMS lab.

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Authors and Affiliations

  1. University of California Davis, 1 Shields Ave, Davis, CA, 95616, USA

    Jessica Dill, Masakazu Soshi & Kazuo Yamazaki

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  1. Jessica Dill
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  2. Masakazu Soshi
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  3. Kazuo Yamazaki
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Correspondence to Masakazu Soshi.

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Dill, J., Soshi, M. & Yamazaki, K. A study on the effect of directed energy deposition substrate energy on clad geometry. Int J Adv Manuf Technol 109, 315–333 (2020). https://doi.org/10.1007/s00170-020-05485-6

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  • DOI: https://doi.org/10.1007/s00170-020-05485-6

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