<p>The effects of Ti-6Al-4V part size on its temperature distribution during the blown-powder directed energy deposition-laser (DED-L) process was investigated through dual-thermographic monitoring and some unique modeling techniques. Results demonstrate that the duration of dwell times presented to be a major contributing factor affecting the rate at which a steady-state temperature field is achieved. As a result, the longer wall took significantly more layers/time to achieve a uniform temperature profile within the wall. Maximum and average melt pool temperatures appear to be near independent of part size at steady state. Finite element simulation results showed that a quasi-steady melt pool temperature may be unique to a layer specially during earlier cladding process near the substrate, and that the layer-wise steady melt pool was achieved within the first few seconds of track scanning. A proposed fin modeling-based temperature distribution was found to accurately predict the thermal profile in a ‘substrate affected zone’ (SAZ) along the scan direction within 5%. A method to predict the onset of the SAZ has also been proposed.&nbsp; Process parameters used for the DED-L of component volumes are not necessarily optimal for thin-walled structures due to there being significantly less thermal capacity and having high surface area to volume ratio.</p>

Monitoring and Modeling of Ti-6al-4v Thin Wall Temperature Distribution During Blown Powder Laser Directed Energy Deposition

Paper Proceedings: https://asmedigitalcollection.asme.org/MSEC/MSEC2021/volume/85062

2021 International Manufacturing Science and Engineering Conference (MSEC2021)

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