Abstract
Blown powder directed energy deposition (DED) hybrid machine tools are particularly beneficial when the net shape of a component is to be manufactured in an additive and machined interleaved fashion. This investigation seeks to analyze the effect of the additive head lean angle relative to the part on blown powder DED surface contamination due to overspray. These hybrid DED platforms are commonly installed on multi-axis machining systems where the lean of the deposition head relative to the component surface can be controlled by tilting the component. The blown powder DED process has a 10-50% lower catchment efficiency as compared to wire fed DED systems. This excess powder is still fed towards the deposition location where the particles are heated by the laser and rebound off the melt pool. Some of these heated particles impact the previously machined thin-wall surface. While the deposition process and tool path planning process has been evaluated, the effect of the overspray due to lean angle of the deposition head on the previously thin-wall machined surface is not yet fully understood. This investigation found that minimum lean angle coincides with minimal overspray effect with nearly no contamination. If a lean angle is required, the maximum lean angle possible should be implemented for the smallest effected overspray area on the machined surface which was found to decrease the affect zone by half compared to intermediate lean angles. A diameter divergence was also noticed as the deposition angle was increased. In this study, a thorough analysis of the surface and geometric effects when depositing thin-walled components at varying angles is completed. It has been shown that part quality can be significantly affected by lean angle and thus must be incorporated as an additional design consideration in the manufacturing process.
| Original language | English |
|---|---|
| Title of host publication | Manufacturing Equipment and Automation; Manufacturing Processes; Manufacturing Systems; Nano/Micro/Meso Manufacturing; Quality and Reliability |
| Publisher | American Society of Mechanical Engineers |
| ISBN (Electronic) | 9780791887240 |
| DOIs | |
| State | Published - 2023 |
| Event | ASME 2023 18th International Manufacturing Science and Engineering Conference, MSEC 2023 - New Brunswick, United States Duration: Jun 12 2023 → Jun 16 2023 |
Publication series
| Name | Proceedings of ASME 2023 18th International Manufacturing Science and Engineering Conference, MSEC 2023 |
|---|---|
| Volume | 2 |
Conference
| Conference | ASME 2023 18th International Manufacturing Science and Engineering Conference, MSEC 2023 |
|---|---|
| Country/Territory | United States |
| City | New Brunswick |
| Period | 06/12/23 → 06/16/23 |
Funding
The authors would like to acknowledge the cooperation and support of Mazak Corporation. The authors would also like to acknowledge Joseph Fletcher, Dennis Brown, Sarah Graham, and Andrés Márquez Rossy. Funding: This work is funded by the Department of Energy DE-EE0008303 with the support of Oak Ridge National Laboratory. This manuscript has been authored by UT-Battelle, LLC under Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy. Research was co-sponsored by the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing Office. This manuscript has been authored by UT-Battelle, LLC, under contract DE-AC05-00OR22725 with the US Department of Energy (DOE). The US government retains and the publisher, by accepting the article for publication, acknowledges that the US government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for US government purposes. DOE will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan).
Keywords
- Blown Powder Directed Energy Deposition
- Directed Energy Deposition
- Hybrid Manufacturing