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Title: Demonstration of thermal control, microstructure control, defect mitigation and process parameter database generation for Ti-6Al-4V Direct Digital Manufacturing - Understanding defect mitigation and process parameter database generation for direct digital manufacturing

Researchers from Manufacturing Demonstration Facility (MDF) at Oak Ridge National Laboratory (ORNL) worked with Applied Optimization (AO) to understand and evaluate the propensity for defect formation in builds manufactured using DM3D-POM laser direct metal deposition. The main aim of this collaboration was to understand the character of powder jet behavior as a function of the nozzle parameters such as cover gas, carrier gas, and shaping gas. In order to evaluate the sensitivities of the parameters used in model, various experiments were performed with in-situ monitoring of the powder stream characteristics using a high speed camera. A wide variety of conditions while keeping the hopper motor rpm constant, including laser power and travel speed were explored. The cross sections of the deposits were characterized using optical microscopy.
 [1] ;  [1] ;  [1] ;  [2] ;  [1] ;  [3] ;  [2]
  1. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
  2. Univ. of Tennessee, Knoxville, TN (United States)
  3. Applied Optimization, Dayton, OH (United States)
Publication Date:
OSTI Identifier:
Report Number(s):
ED2701000; CEED492
DOE Contract Number:
Resource Type:
Technical Report
Research Org:
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States). Manufacturing Demonstration Facility (MDF)
Sponsoring Org:
USDOE Office of Energy Efficiency and Renewable Energy (EERE)
Country of Publication:
United States