TY - GEN
T1 - EFFECT OF BLOWN POWDER DIRECTED ENERGY DEPOSITION ANGLE ON OVERSPRAY CONTAMINATION
AU - Heinrich, Lauren
AU - Kannan, Rangasayee
AU - Burl, Alan
AU - Nandwana, Peeyush
AU - Fillingim, Kenton
AU - Feldhausen, Thomas
AU - Kurfess, Thomas
AU - Saldaña, Christopher
N1 - Publisher Copyright:
Copyright © 2023 by ASME and The United States Government.
PY - 2023
Y1 - 2023
N2 - 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.
AB - 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.
KW - Blown Powder Directed Energy Deposition
KW - Directed Energy Deposition
KW - Hybrid Manufacturing
UR - http://www.scopus.com/inward/record.url?scp=85176785740&partnerID=8YFLogxK
U2 - 10.1115/msec2023-104372
DO - 10.1115/msec2023-104372
M3 - Conference contribution
AN - SCOPUS:85176785740
T3 - Proceedings of ASME 2023 18th International Manufacturing Science and Engineering Conference, MSEC 2023
BT - Manufacturing Equipment and Automation; Manufacturing Processes; Manufacturing Systems; Nano/Micro/Meso Manufacturing; Quality and Reliability
PB - American Society of Mechanical Engineers
T2 - ASME 2023 18th International Manufacturing Science and Engineering Conference, MSEC 2023
Y2 - 12 June 2023 through 16 June 2023
ER -