Area-based composition predictions of materials fabricated using simultaneous wire-powder-directed energy deposition
Year: 2024
Type: article
Abstract: Functionally graded materials are an emergent method for designing components with programmable site-specific material properties. These materials are typically fabricated using metal additive manufacturing tools by simultaneously feeding multiple wire and/or powder feedstocks at various rates to achieve spatial composition change. The wire-powder-directed energy deposition (WP-DED) technique is of particular interest for many functionally graded material applications by balancing the low raw materials cost of wire with the high resolution of powder. However, feeding wire and powder are inherently different processes since all extruded wire enters the melt pool, while much of the blown powder is scattered, which makes determining the composition of the build challenging. In this study, we devise a simple area-based measurement method for estimating the composition of WP-DED structures. WP-DED single beads are printed using 309L stainless steel wire and commercially pure Fe powder at five wire feed rates (0.5, 0.75, 1.00, 1.25, 1.50 mm/mm) and five powder feed rates (2, 4, 6, 8, 10 rpm). Characteristic defects including interface gaps and macrosegregation (lack of mixing) tendencies are examined. High powder feed rates (8, 10 rpm) result in interface gaps at all wire feed rates, but smooth deposition and complete mixing is achieved at low powder feed rates, particularly with lower wire feed rates as well. The area-based composition measurement method is within ±20% of energy dispersive x-ray spectroscopy measurements for all samples, showing its effectiveness as a rapid composition estimate for WP-DED materials development.
Source: Additive Manufacturing Letters
Institution: Oregon State University
Language: English
Subfield: Mechanical Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: gold
Estimated APC paid: $1,250
Awards: THIS PROJECT WILL PROVIDE NECESSARY APPLIED RESEARCH AND DEVELOPMENT (R&D) TO SUPPORT OPEN-WATER TESTING AT PACWAVE SOUTH. PACWAVE SOUTH IS A PRE-PERMITTED, HIGHLY-ENERGETIC, AND GRID-CONNECTED DEEP-WATER WAVE ENERGY TESTING FACILITY THAT ENABLES SYSTEM AND COMPONENT TESTING ACROSS A RANGE OF SCALES OF MARINE ENERGY TECHNOLOGIES. PACWAVE WILL PLAY A CRITICAL ROLE IN THE DEVELOPMENT OF THE WAVE ENERGY CONVERTER (WEC) INDUSTRY AND EARLY PACWAVE TESTING CAMPAIGNS WILL SIGNIFICANTLY ADVANCE WEC TECHNOLOGIES., G497139189, NNCI: Northwest Nanotechnology Infrastructure (NNI)
OpenAlex ID: W4404032324