MEPE34 Additive Manufacturing: Dr. N. Siva Shanmugam

Dr. N.
Siva Shanmugam, Department of Mechanical Engineering
MEPE34
Additive Manufacturing
Dr. N. Siva Shanmugam

Associate Professor
Department of Mechanical Engineering
National Institute of Technology
Tiruchirappalli – 15
Email: [email protected]
Mobile: 9443649278
National Institute of Technology, Trichy

Dr. N. Siva Shanmugam, Department of Mechanical Engineering
Directed Energy Deposition (DED)

Directed Energy Deposition (DED) is a 3D printing method which uses a focused
energy source, such as a plasma arc, laser or electron beam to melt a material which
is simultaneously deposited by a nozzle. As with other additive manufacturing
processes, DED systems can be used to add material to existing components, for
repairs, or occasionally to build new parts.
The DED process is known by other names, including Laser Engineered Net Shaping
(LENS), Direct Metal Deposition (DMD), Electron Beam Additive Manufacturing
(EBAM), Directed Light Fabrication, and 3D Laser Cladding, depending on the exact
application or method used.

Directed Energy Deposition (DED)

DED uses a heat source to melt a powder or wire as it is deposited onto the
surface of an object. While powder provides greater accuracy in
deposition, wire is more efficient with regards to material use.
The material is added layer-by-layer and solidifies from the melt pool to
create new features. Layers are typically 0.25mm to 0.5mm thick. The
cooling times for materials are very fast at around 1000-5000 °C per
second. The cooling time affects the final grain structure although
overlapping in the material can cause re-melting, which creates a uniform
but alternating microstructure.
In most cases, the object remains in a fixed position while the arm moves
to lay down the material. However, this can be reversed with the use of a
platform, which moves while the arm remains stationary.

Direct Energy Deposition – Step by Step
1. A4 or 5 axis arm with nozzle moves around a

fixed object.
2. Material is deposited from the nozzle onto
existing surfaces of the object.
3. Material is either provided in wire or powder
form.
4. Material is melted using a laser, electron beam
or plasma arc upon deposition.
5. Further material is added layer by layer and
solidifies, creating or repairing new material
features on the existing object.

What are the Advantages of DED?

The advantages of Directed Energy Deposition include the ability to control the grain
structure, which allows the process to be used for the repair of high quality
functional parts. This does require a balance between accuracy and speed, since
higher speeds equal a lower level of accuracy and a less consistent microstructure.
DED allows for the production of relatively large parts with minimal tooling.
This process also allows for the creation of components with composition gradients
or hybrid structures using multiple materials with differing compositions
What are the Disadvantages of DED?

The finish created will vary depending on the material used and may require some
post processing to achieve the desired effect. The material use for DED is still
relatively limited and fusion-based processes still require further research to move
them into mainstream use.

Applications
Directed Energy Deposition can be used to fabricate parts, but is generally used for
repair or to add material to existing components. Generally-speaking, the applications
for DED fall into three categories; near-net-shape parts, feature additions, and repair.
Near-Net-Shape Parts
DED can produce similar parts to those created with conventional machining. This
means that, for DED to be chosen, these parts need to be for applications where
conventional manufacture is expensive or slow. This makes the process ideal for
producing machined parts from expensive or hard to cut metals.
As a result, DED lends itself to the production of items such as aerospace brackets,
tanks, and ribs. Near-Net-Shape part manufacture tends to be used primarily within
the aerospace, defence, power and marine sectors. While this process can offer
improved product design, time saving and cost reductions, it is not deemed suitable for
small, high volume applications due to the fixed price structure and post processing
requirements.

Feature Addition
Since DED can be used to print onto existing parts it is ideal for adding additional
features to existing parts. Advances in multi-axis robotics and software has allowed
for increasingly complex shapes to be built, which is particularly useful if the added
feature is expensive to produce with conventional techniques.
DED also allows for multiple metals to be used by changing the feedstock while
printing. To achieve this successfully there are important technical considerations
around design and bonding properties for dissimilar metals.
Repair
Direct Energy Deposition is increasingly replacing conventional methods for the
repair of parts. Since it is an automated process, DED provides high levels of control
and repeatability, which is particularly important for complex and precise parts. The
process is already used for applications such as the repair of damaged turbine blades
or propellers.

Powder bed fusion (PBF)

Powder bed fusion (PBF) is an additive manufacturing process and works on the
same basic principle in that parts are formed through adding material rather
than subtracting it through conventional forming operations such as milling.
The PBF process begins with the creation of a 3D CAD model, which is numerically
'sliced' into several discrete layers. For each layer, a heat source scan path is
calculated which defines both the boundary contour and some form of fill sequence,
often a raster pattern since the heat source is typically an energy beam (e.g. a laser).

Powder bed fusion (PBF)

Each layer is then sequentially bonded on top of each other. PBF processes spread
powdered material over the previously joined layer, ready for processing of the next
layer hence the manufacturing is discrete rather than continuous (though each layer is
fully consolidated to adjacent layers).
A hopper supplies the powdered material which is then spread uniformly over the
powder bed build platform area via a roller or blade. The optimal thickness of each
layer of spread powder is dependent on the processing conditions and material used,
but values of 25 to 100µm are common.
What are the Different Types of Powder Bed Fusion?

There are several variants of PBF, which are designated by the heat source used and
the type of material joined. The two dominant types are laser beam (PBF-LB) and
electron beam (PBF-EB) and have trademarked technologies under each. Each variant
offers advantages and disadvantages, so suitability should be weighed on an
application by application basis.


Selective Laser Sintering (SLS)

SLS is a trademarked term and is PBF-LB. The process typically sinters powdered
polymer materials such as nylon and polyetherketoneketone (PEKK).
Selective Laser Melting (SLM)
SLM is a trademarked term and comparable to SLS in that a laser is used to provide
heat (therefore falling under PBF-LB), however the laser fully melts the powder
rather than sintering it. The process is applied to metal powders such as:
aluminium alloys; titanium and its alloys; and stainless steel.
More exotic metals (e.g., tungsten) can be processed but tend to be more
application based. An inert atmosphere (typically argon) is included in the build
chamber to prevent oxidation and/or nitriding of the consolidated material.
Electron Beam Melting (EBM)
EBM is a comparable process to SLM, replacing the laser with an electron gun
(hence a PBF-EB process). Owing to the use of an electron beam, the build
chamber utilizes a vacuum instead of an inert atmosphere, though a small
amount of inert gas (typically helium) is used to allow better process control.

Post Processing
Post processing of PBF parts is commonly required to
better enable them in their intended applications: this
is particularly true for metals and alloys. This might
occur for the following reasons:
• Improve mechanical properties (via heat treatment)

• Reduce residual stress (via heat treatment)
• Improve surface finish (via chemical or laser
polishing, and/or abrasive grit blasting)

What are the Advantages of Powder Bed Fusion?

Power bed fusion advantages include:
• Reduced material wastage and cost (superior buy-to-fly ratio)
• Improved production development times
• Enablement of rapid prototyping and low volume production
• Capable of building functionally graded parts
• Fully customised parts on a batch by batch basis, eliminating fixed
designs
• Good resolution when compared to other additive manufacturing
processes
• Efficient recycling of un-melted powder
• Ability to join many material grades, including ceramics, glass,
plastics, metals and alloys
• Elimination of the need for machining fixtures

CLASSIFICATION OF MAIN AM PROCESSES

INTRODUCTION
➢ Additive manufacturing (AM) is a technology that promises to reduce part
cost by reducing material wastage and time to market.
➢ In the WAAM process, 3D metallic components are built by depositing
beads of weld metal in a layer by layer fashion.
➢ Finally, WAALM can be used to deposit a variety of materials that can be
welded such as steel, Ni alloys and Ti alloys.

INSITES ABOUT THIS TECHNOLOGY

➢ Although the wire-added ALM process has been around for almost a century
– the first patent was filed 1920 by Baker – modern welding and automation
technologies provide opportunities that were not previously available.
➢ This technology adopts arc welding tools and wire as feedstock for additive
manufacturing purposes.
➢ High deposition rates, low material and equipment costs and good
structural integrity make Wire + Arc Additive Manufacturing a suitable
candidate for replacing the current method of manufacturing from solid
billets or large forgings, especially with regards to low and medium
complexity parts.
➢ There is a pressing need for the development of a process that could replace
the current method of manufacturing large structures such as cruciforms,
stiffened panels, wing ribs, etc., which are machined from billets or large
forgings, with unsustainable buy/fly (BTF) ratios.

BTF Ratio
➢ BTF ratio is defined as the ratio of the volume or mass of the
initial workpiece to that of the finished product.
➢ The BTF ratio depends on how close the shape of forgings or

ingots are to the shape of the finished component.
Massinitial
BTF =
Mass final

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Dr. N.

Siva Shanmugam, Department of Mechanical Engineering

Dr. N. Siva Shanmugam

National Institute of Technology, Trichy

Directed Energy Deposition (DED)

National Institute of Technology, Trichy

Directed Energy Deposition (DED)

National Institute of Technology, Trichy

Direct Energy Deposition – Step by Step

1. A4 or 5 axis arm with nozzle moves around a

National Institute of Technology, Trichy

What are the Advantages of DED?

What are the Disadvantages of DED?

National Institute of Technology, Trichy

National Institute of Technology, Trichy

National Institute of Technology, Trichy

Powder bed fusion (PBF)

National Institute of Technology, Trichy

Powder bed fusion (PBF)

What are the Different Types of Powder Bed Fusion?

National Institute of Technology, Trichy

National Institute of Technology, Trichy

Selective Laser Sintering (SLS)

National Institute of Technology, Trichy

• Improve mechanical properties (via heat treatment)

National Institute of Technology, Trichy

What are the Advantages of Powder Bed Fusion?

National Institute of Technology, Trichy

CLASSIFICATION OF MAIN AM PROCESSES

National Institute of Technology, Trichy

National Institute of Technology, Trichy

INSITES ABOUT THIS TECHNOLOGY

National Institute of Technology, Trichy

➢ The BTF ratio depends on how close the shape of forgings or

National Institute of Technology, Trichy

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