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

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Abstract

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.

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Acknowledgements

The authors would like to acknowledge the cooperation and support of the Mazak Corporation and Autodesk. The authors would also like to acknowledge Dennis Brown,and Matt Sallas for their contributions.

Funding

We would also like to thank the Department of Energy for funding this work via DE-EE0008303. This work was supported by the US Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing Office, under contract number DE-AC05-00OR22725.

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Omar Elsayed: Conceptualization, data curation, formal analysis, project administration, and writing (original draft); Venkata Surya Karthik Adapa: conceptualization, data curation, formal analysis, and writing (original draft); Samuel Kersten, Derek Vaughan, Christopher Masuo, Myong Joon Kim, Thomas Feldhausen, and Thomas Kurfess: data curation and investigation; Christopher Saldana: conceptualization, project administration, supervision, and writing (review and editing).

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Correspondence to Venkata Surya Karthik Adapa.

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Elsayed, O., Adapa, V.S.K., Kersten, S. et al. Effects of lead and lean in multi-axis directed energy deposition. Int J Adv Manuf Technol 125, 5119–5134 (2023). https://doi.org/10.1007/s00170-023-11085-x

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  • DOI: https://doi.org/10.1007/s00170-023-11085-x

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