Origin of deposition errors and layer-wise control strategies during laser additive manufacturing
Although additive manufacturing (AM) is a net/near-net forming process, significant deviations may occur between the finally manufactured product and the designed object. This study is inspired by the deposition errors in a typical closed-contour structure manufactured via laser-directed energy depo...
| Main Authors: | , , , , , , |
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| Format: | Article |
| Language: | English |
| Published: |
Taylor & Francis Group
2023-12-01
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| Series: | Virtual and Physical Prototyping |
| Subjects: | |
| Online Access: | http://dx.doi.org/10.1080/17452759.2023.2173615 |
| _version_ | 1827811255317954560 |
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| author | Yiming Mao Huiliang Wei Lili Chang Jiashun Yue Tingting Liu Fei Xing Wenhe Liao |
| author_facet | Yiming Mao Huiliang Wei Lili Chang Jiashun Yue Tingting Liu Fei Xing Wenhe Liao |
| author_sort | Yiming Mao |
| collection | DOAJ |
| description | Although additive manufacturing (AM) is a net/near-net forming process, significant deviations may occur between the finally manufactured product and the designed object. This study is inspired by the deposition errors in a typical closed-contour structure manufactured via laser-directed energy deposition (DED). A series of experiments were carried out and a multi-physics mechanistic model was developed to reveal the origins and the spatiotemporal variations of the errors in representative processes. The results demonstrate that the irregularity of the deposition can be initiated by the liquid metal flow in the molten pool driven by forces including the recoil pressure and surface tension. The deviations are subsequently aggravated due to the inheritance between layers. Supported by the revealed underlying mechanisms, solution strategies including layer-wise dynamic compensations are thus proposed. The novel scientific findings can be insightful to researches for other metal AM processes and structures considering the universality of the uncovered mechanisms. |
| first_indexed | 2024-03-11T23:02:21Z |
| format | Article |
| id | doaj.art-339eaee2b9c74a5591d7c5691cc992d3 |
| institution | Directory Open Access Journal |
| issn | 1745-2759 1745-2767 |
| language | English |
| last_indexed | 2024-03-11T23:02:21Z |
| publishDate | 2023-12-01 |
| publisher | Taylor & Francis Group |
| record_format | Article |
| series | Virtual and Physical Prototyping |
| spelling | doaj.art-339eaee2b9c74a5591d7c5691cc992d32023-09-21T14:38:04ZengTaylor & Francis GroupVirtual and Physical Prototyping1745-27591745-27672023-12-0118110.1080/17452759.2023.21736152173615Origin of deposition errors and layer-wise control strategies during laser additive manufacturingYiming Mao0Huiliang Wei1Lili Chang2Jiashun Yue3Tingting Liu4Fei Xing5Wenhe Liao6Nanjing University of Science and TechnologyNanjing University of Science and TechnologyNanjing University of Aeronautics and AstronauticsNanjing University of Science and TechnologyNanjing University of Science and TechnologyNanjing Zhongke Raycham Laser Technology Co., Ltd.Nanjing University of Science and TechnologyAlthough additive manufacturing (AM) is a net/near-net forming process, significant deviations may occur between the finally manufactured product and the designed object. This study is inspired by the deposition errors in a typical closed-contour structure manufactured via laser-directed energy deposition (DED). A series of experiments were carried out and a multi-physics mechanistic model was developed to reveal the origins and the spatiotemporal variations of the errors in representative processes. The results demonstrate that the irregularity of the deposition can be initiated by the liquid metal flow in the molten pool driven by forces including the recoil pressure and surface tension. The deviations are subsequently aggravated due to the inheritance between layers. Supported by the revealed underlying mechanisms, solution strategies including layer-wise dynamic compensations are thus proposed. The novel scientific findings can be insightful to researches for other metal AM processes and structures considering the universality of the uncovered mechanisms.http://dx.doi.org/10.1080/17452759.2023.2173615additive manufacturingdeposition errormolten poolliquid metal flowerror controlmelting and solidification |
| spellingShingle | Yiming Mao Huiliang Wei Lili Chang Jiashun Yue Tingting Liu Fei Xing Wenhe Liao Origin of deposition errors and layer-wise control strategies during laser additive manufacturing Virtual and Physical Prototyping additive manufacturing deposition error molten pool liquid metal flow error control melting and solidification |
| title | Origin of deposition errors and layer-wise control strategies during laser additive manufacturing |
| title_full | Origin of deposition errors and layer-wise control strategies during laser additive manufacturing |
| title_fullStr | Origin of deposition errors and layer-wise control strategies during laser additive manufacturing |
| title_full_unstemmed | Origin of deposition errors and layer-wise control strategies during laser additive manufacturing |
| title_short | Origin of deposition errors and layer-wise control strategies during laser additive manufacturing |
| title_sort | origin of deposition errors and layer wise control strategies during laser additive manufacturing |
| topic | additive manufacturing deposition error molten pool liquid metal flow error control melting and solidification |
| url | http://dx.doi.org/10.1080/17452759.2023.2173615 |
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