Effects of lead and lean in multi-axis directed energy deposition

Elsayed, Omar; Adapa, Venkata Surya Karthik; Kersten, Samuel; Vaughan, Derek; Masuo, Christopher; Kim, Myong Joon; Feldhausen, Thomas; Saldana, Christopher; Kurfess, Thomas

doi:10.1007/s00170-023-11085-x

Effects of lead and lean in multi-axis directed energy deposition

Journal Article · Mon Feb 13 00:00:00 EST 2023 · International Journal of Advanced Manufacturing Technology

DOI:https://doi.org/10.1007/s00170-023-11085-x· OSTI ID:1928950

Elsayed, Omar ^[1]; Adapa, Venkata Surya Karthik ^[1]; Kersten, Samuel ^[1]; Vaughan, Derek ^[1]; Masuo, Christopher ^[1]; Kim, Myong Joon ^[1]; Feldhausen, Thomas ^[2]; Saldana, Christopher ^[1]; Kurfess, Thomas ^[1]

Georgia Institute of Technology, Atlanta, GA (United States)
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Here, the present study examines the effect of varying laser incidence angles on textural, microstructural, and geometric characteristics of directed energy deposition (DED) processed materials, providing a more comprehensive outlook on participating laser-matter interaction phenomena and ultimately devising strategies to ameliorate print performance. In this study, single-layer, single-/multi-track specimens were processed to examine the effect of non-orthogonal angular configurations on bead morphology, microstructure, phase composition, and textural representation of DED-processed 316L stainless steel materials. It was observed that bead size decreased at increasing lead and lean angles. Asymmetry in the distribution of the bead morphology as a function of lead angle indicates better catchment for acute lead angle configurations over obtuse configurations. No significant differences in phase composition, texture, and microstructure were observed in moderate off-axis configurations. When the penetration depth for the deposits was below 20 μm, columnar structures dominated the microstructure of the deposited material. At deeper penetration depths, columnar and equiaxed structures were observed at the bead-substrate interface and center of the bead, respectively. Compared to powder-blown DED, wire-DED dilution profiles were found to be asymmetric in both orthogonal and non-orthogonal wire DED samples.

View Accepted Manuscript (DOE)

Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE)

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 1928950

Journal Information:: International Journal of Advanced Manufacturing Technology, Journal Name: International Journal of Advanced Manufacturing Technology Journal Issue: 11-12 Vol. 125; ISSN 0268-3768

Publisher:: SpringerCopyright Statement

Country of Publication:: United States

Language:: English

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