27-Nov-21

Directed Energy Deposition (DED) Processes

Radha Raman Mishra, Ph. D.

Course Instructor & Assistant Professor
Department of Mechanical Engineering

This chapter
Introduction

Basic principles

Classification
DED
Process
Process parameters

Electron beam-based DED

Benefits and Drawbacks

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Introduction
• DED Process enable the creation of parts by melting material while depositing

• NOT used to melt a material that is pre-laid in a powder bed (like PBF).

• The basic approach can work for polymers, ceramics, and metal matrix composites

• Predominantly used for metal powders

• Often referred to as “metal deposition” technology

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Ian Gibson, David W. Rosen, Brent Stucker, Additive manufacturing technologies: rapid prototyping to direct digital manufacturing Springer, 2010.

Classification

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Dass, A., & Moridi, A. (2019). State of the art in directed energy deposition: From additive manufacturing to materials design. Coatings, 9(7), 418.

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Powder-Based DED

(a) Coaxial feeding: a higher capture efficiency of powder, and protect the melt pool from oxidation

(b) Single nozzle feeding: apparatus simplicity, economical, and ability to deposit material into tight
locations; however, melt pool geometry is direction specific
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Dass, A., & Moridi, A. (2019). State of the art in directed energy deposition: From additive manufacturing to materials design. Coatings, 9(7), 418.

Wire-based DED

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Dass, A., & Moridi, A. (2019). State of the art in directed energy deposition: From additive manufacturing to materials design. Coatings, 9(7), 418.

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Basic Principles

Schematic illustrating laser optics and energy density

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Ian Gibson, David W. Rosen, Brent Stucker, Additive manufacturing technologies: rapid prototyping to direct digital manufacturing Springer, 2010.

Process Parameters

Process Parameters:
• Track scan spacing
• Powder feed rate
• Beam traverse speed
• Beam power and
• Beam spot size
• Feedstock material properties

Dilution (D) = d/ (h+d)

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Ian Gibson, David W. Rosen, Brent Stucker, Additive manufacturing technologies: rapid prototyping to direct digital manufacturing Springer, 2010.

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Generic (Laser-based) DED process

Complex 3-D geometry: requires either support material or
a multi-axis deposition head.

LENS-deposited Ti/TiC metal matrix composite structure

Laser-Based Metal
Deposition (LBMD)
is more popular

Schematic of a typical laser powder DED process DED of CoCrMo

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Ian Gibson, David W. Rosen, Brent Stucker, Additive manufacturing technologies: rapid prototyping to direct digital manufacturing Springer, 2010.

Electron Beam-Based DED

• Electron Beam Freeform Fabrication (EBF3) was

developed by NASA Langley, USA,

• To fabricate and/or repair aerospace structures

both terrestrially and in future space-based systems

• Uses wire feeder

• Advantages
 More efficient in converting electrical energy into a beam than most lasers
 Work effectively in a vacuum but not in the presence of inert gases
 Well suited for the space environment
 Wire feeding is preferred for low-gravity environments
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Ian Gibson, David W. Rosen, Brent Stucker, Additive manufacturing technologies: rapid prototyping to direct digital manufacturing Springer, 2010.

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Benefits and drawbacks

• Benefits
 Fully dense parts with unparalleled control of microstructure
 Effectively repairing and refurbishing defective and service damaged parts
 Producing of in-situ generated composite and heterogeneous material parts

• Drawbacks
 Poor resolution and
 Surface finish (> 25 μm)
 Poor accuracy (> 0.25 mm)
 Slower build speed

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Ian Gibson, David W. Rosen, Brent Stucker, Additive manufacturing technologies: rapid prototyping to direct digital manufacturing Springer, 2010.

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