Processing optimization in directed energy deposition of aluminium alloy powders
Year: 2025
Type: article
Abstract: Aluminium alloys present significant challenges for metal additive manufacturing (AM) due to their susceptibility to solidification cracking and porosity. To address this, a comprehensive framework has been developed to optimize Directed Energy Deposition (DED) parameters, beginning with gas atomized Al6061 powders as a representative system. Single-track DED experiments are systematically performed across a matrix of laser powers and scan speeds, guided by a central composite design embedded within a response surface methodology framework. Melt pool geometries, including width, depth, and aspect ratio, are characterized to understand the primary process responses. Planned cross-sectional microstructural analysis will quantify Secondary Dendrite Arm Spacing as a metric for cooling rate assessment, thereby linking thermal conditions to microstructural refinement. Based on the identified optimal processing window, subsequent work will involve layer-wise printing trials with customized toolpath strategies to evaluate their influence on solidification cracking behaviour and internal defect distribution. By combining validated feedstock insights, quantitative microstructure–process mapping, and toolpath-driven thermal management strategies, this work aims to advance the tailored processing of aluminium alloys for structural and defect-sensitive additive manufacturing applications.
Language: English
Subfield: Mechanical Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: green
Funder: European Commission
OpenAlex ID: W6930780304
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