Optimization of hybrid Directed Energy Deposition through production and microstructure assessment

Research output: Chapter in Book/Report/Conference proceedingConference paper

Abstract

Hybrid Laser-based Directed Energy Deposition (DED-LB) offers advantages over conventional Additive Manufacturing (AM) techniques, enabling the production of more complex parts with integrated functionalities, and potentially mitigating low fatigue performances. This study focuses on optimizing a hybrid DED-LB process for tower samples with integrated capillaries, achieved through combining DED-LB with milling and drilling operations. Thermal gradients introduced during both additive and subtractive processes are inherent and known challenges of hybrid DED-LB. To address these challenges, in-situ monitoring with high-speed cameras is exploited to analyse the melt pool quality and to optimize process parameters aimed at minimizing defects. Different printing strategies, focusing on scan patterns and energy densities, are compared regarding part geometry, porosity, and microstructure. The influence of process parameters on microstructure is investigated, using optical microscopy and Electron Backscatter Diffraction (EBSD), to achieve defect-minimized and microstructure-controlled production. Observed changes in grain characteristics (crystallographic texture, grain morphology, and size), linked to cooling rates, guide process optimisation. Identifying and addressing production challenges pave the way for the manufacturing of reliable, high-performance components using hybrid DED-LB.
Original languageEnglish
Title of host publication13th CIRP Conference on Photonic Technologies [LANE 2024]
PublisherElsevier
Pages324-330
Number of pages7
Volume124
DOIs
Publication statusPublished - 11 Sep 2024
Event13th CIRP Conference on Photonic Technologies - Fürth, Germany
Duration: 15 Sep 202419 Sep 2024

Publication series

NameProcedia CIRP
PublisherElsevier
ISSN (Print)2212-8271

Conference

Conference13th CIRP Conference on Photonic Technologies
Abbreviated titleCIRP
Country/TerritoryGermany
CityFürth
Period15/09/2419/09/24

Bibliographical note

Zoé Jardon was born in Uccle, Belgium, in 1993. She received the degree in electro-mechanical engineering in 2016 from the Vrije Universiteit Brussel (VUB) and Université Libre de Bruxelles (ULB) according to the BRUFACE program. In 2016 she joined the Post-Graduate Research Master program of the von Karman Institute for Fluid Dynamics in the department of Environmental and Applied Fluid Dynamics. In 2017 she joined the Department of Mechanical Engineering (MECH) of the Vrije Universiteit Brussel in the Additive Manufacturing Research Lab (AM-lab) where she obtained her Ph.D. in 2022 in collaboration with the von Karman Institute. She is currently a post-doc researcher in the AM-lab, financed by an FWO junior post-doc fellowship. Her main research interests are situated in the field of additive manufacturing, fluid dynamics, aeroacoustics and Structural Health Monitoring.

Keywords

  • Hybrid Additive Manufacturing
  • Directed Energy Deposition
  • in-situ monitoring
  • microstructure control
  • defect minimization

Cite this