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Advances in Additive Manufacturing Using Laser, Electron Beam, and Arc Directed Energy Deposition

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (31 December 2023) | Viewed by 5748

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Dr. Abhay Sharma

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Department of Materials Engineering, KU Leuven, Campus De Nayer, 2860 Sint-Katelijne Waver, Belgium
Interests: welding engineering; process modelling; additive manufacturing
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Special Issue Information

Dear Colleagues,

After several decades of insightful investigations, direct energy deposition (DED) techniques have matured to tackle the specific challenges concerning additive manufacturing large-scale metallic components. In recent times, there has been rapid growth in laser-, electron beam- and arc-directed energy deposition-based additive manufacturing. To this end, the growth is multi-directional in different verticals such as process, materials, design, and numerical. More often than before, the amalgamation of more than one vertical in research shows the development of a comprehensive understanding of the complete process chain, including post-processing. Therefore, the production of industrial components using DED is expected to shortly register tremendous growth. With an aim to assist this growth, the Special Issue is planned to report some of the fundamental and applied research outcomes and case studies on the component-level implementation of the DED.

The potential topics for the Special Issues include, but are not limited to:

DED processes;
Laser and electron beam and wire-arc additive manufacturing;
New process variants and hybrid additive manufacturing;
DED of new materials, bimetallic and functionally graded materials;
Residual stress and distortion;
Design for additive manufacturing;
Numerical modelling and simulation;
Mechanical and metallurgical characterization;
Case studies on DED application in the production of industrial components.

Prof. Dr. Abhay Sharma
Guest Editor

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Keywords

additive manufacturing
DED
WAAM
laser
electron beam
residual stress
multi-material

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Published Papers (3 papers)

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Research

19 pages, 18885 KiB

Open AccessArticle

Statistical Analysis of Morphological Characteristics of Inconel 718 Formed by High Deposition Rate and High Laser Power Laser Cladding

by Yanhua Bian, Xiuli He, Chongxin Tian, Jianhao Guo, Bo Chen, Binxin Dong, Shaoxia Li and Gang Yu

Materials 2024, 17(3), 638; https://doi.org/10.3390/ma17030638 - 28 Jan 2024

Viewed by 1176

Abstract

Laser cladding is one of the emerging additive manufacturing technologies and has been adopted in various industrial fields. In this study, the morphological characteristics of a single clad of Inconel 718 manufactured by coaxial laser cladding with high laser power from 4200 W to 5400 W, powder feeding rate from 25 g/min to 50 g/min, and cladding speed from 20 mm/s to 50 mm/s are studied. The cross-section of the melt pool is analyzed and classified by type into three types: shallow dilution, flat dilution, and fluctuating dilution. Nine parameters are designed to describe the morphological characteristics of the clad, and the corresponding linear regression models are developed to establish a quantitative relationship between the combined process parameters and morphological characteristics. The results indicate that the total area of the cross-section A, the clad area above the substrate A_c, the area of the molten substrate A_m, the total height of the cross-section H, the height of the clad above the substrate h_c, the penetration depth h_m, the clad width W, the dilution ratio D, and the wetting angle θ are determined by complex coupling of energy input and mass accumulation, and they are proportional to PF^0.4/V, P^0.5F/V, P/F^0.2/V^0.4, P²F^0.6/V, PF^0.7/V, P²/F/V^0.3, P/V^0.8, P/FV^0.2, and PF⁷/V^0.8, respectively. The large linear regression coefficients and the analysis residuals indicate the high reliability of the statistical linear regression models. This work aims to provide a comprehensive understanding of the influence of the main processing parameters on the morphological characteristics of the clad, which is of great value in providing a reference and laying a basis for the practical application of laser cladding technology at a high deposition rate. Full article

(This article belongs to the Special Issue Advances in Additive Manufacturing Using Laser, Electron Beam, and Arc Directed Energy Deposition)

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14 pages, 16065 KiB

Open AccessArticle

Microstructure and Properties of Electromagnetic Field-Assisted Laser-Clad Norem02 Iron-Based Cemented Carbide Coating

by Zixue Wang, Wanyuan Gui, Jiacheng Fu, Ping Zhu and Yonghao Lu

Materials 2023, 16(20), 6774; https://doi.org/10.3390/ma16206774 - 19 Oct 2023

Cited by 4 | Viewed by 1532

Abstract

An electromagnetic field-assisted (EMF-assisted) laser cladding technique was used to prepare Norem02 iron-based cemented carbide coatings on 304 stainless steels. The coatings then were characterized in terms of their microstructure, microhardness, residual stress, and wear resistance. The results indicated that EMF did not change the phase composition of the Norem02 iron-based cemented carbide coating, but significantly affected its microstructure and properties. EMF accelerated the formation of more uniform and refined microstructure. With an increasing current intensity of EMF to 40 A, the dendritic and columnar crystal structure of the coating gradually transformed into uniform and fine equiaxed grains. However, when the EMF current intensity was increased to 80 A, a small number of small dendrites and columnar crystals began to appear at the top and bottom of the coating. Accordingly, the microhardness first increased, then decreased, and achieved a max of 376.9 HV_0.2 at EMF current intensity of 40 A. EMF also improved the wear resistance of the coatings, reduced the cracking sensitivity, and reduced residual stress on the surface by 45.2%. Full article

(This article belongs to the Special Issue Advances in Additive Manufacturing Using Laser, Electron Beam, and Arc Directed Energy Deposition)

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20 pages, 8631 KiB

Open AccessArticle

Machining Strategy Determination for Single- and Multi-Material Wire and Arc Additive Manufactured Thin-Walled Parts

by Ozan Can Ozaner, Damjan Klobčar and Abhay Sharma

Materials 2023, 16(5), 2055; https://doi.org/10.3390/ma16052055 - 2 Mar 2023

Cited by 5 | Viewed by 2507

Abstract

Wire and arc additive manufacturing (WAAM) technology has recently become attractive due to the fact of its high production capacity and flexible deposition strategy. One of the most prominent drawbacks of WAAM is surface irregularity. Therefore, WAAMed parts cannot be used as built; they require secondary machining operations. However, performing such operations is challenging due to the fact of high waviness. Selecting an appropriate cutting strategy is also challenging, because surface irregularity makes cutting forces unstable. The present research determines the most suitable machining strategy by assessing the specific cutting energy and local machined volume. Up- and down-milling are evaluated by calculating the removed volume and specific cutting energy for creep-resistant steel, stainless steel, and their combination. It is shown that the main factors that affect the machinability of WAAMed parts are the machined volume and specific cutting energy rather than the axial and radial depths of the cut due to the fact of high surface irregularity. Even though the results were unstable, a surface roughness of 0.1 µm was obtained with up-milling. Despite a two-fold difference in the hardness between the two materials in the multi-material deposition, it is found that hardness should not be used as a criterion for as-built surface processing. In addition, the results show no machinability difference between multi- and single-material components for a low machined volume and low surface irregularity. Full article

(This article belongs to the Special Issue Advances in Additive Manufacturing Using Laser, Electron Beam, and Arc Directed Energy Deposition)

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