B.Tech.

Projects
Department of Mechanical Engineering,
Indian Institute of Technology Dharwad, KA, INDIA
2018 Batch

Thermo-Mechanical modelling of Hybrid Powder and Wire feed

Additive Manufacturing process
Siddarth Adappa1, Dr. Somashekara M.A2
1
180030039@iitdh.ac.in
2
Somashekara@iitdh.ac.in

Abstract:

Directed energy deposition (DED) processes enable us to create parts by melting material as it is being deposited,
it is predominantly used for metal powders and wires and the mechanical properties of these products sometimes
exceeds castings made by the same material. Most direct laser deposition processes utilize either feedstock to
obtain near net shape objects and each feeding method has its own advantages and disadvantages. The powder
feed additive manufacturing process is known for higher geometrical accuracy, resolution and power consumption
but their drawbacks include low deposition efficiency, higher temperature gradients, exposure to oxidation and
high cost for manufacturing of spherical base material. Simulations were conducted for deposition of various scan
patterns with powder laser deposition process. The representative patterns, namely, Bi-directional Pattern, Out-
to-In Pattern and Fractal Curves. The results from all three patterns were compared for transient temperature
distribution of melt pool, end point temperature, distortion and manufacturability. Experimental tests were
conducted to validate the results from the simulation. Inconel 718 powder was deposited on SS316 steel in the
representative patterns in the experiment, substrate temperature and residual stress were measured.

Wire DED also possesses a number of benefits that include high deposition rates, cheaper manufacturing, lower
temperature gradients and higher print speeds. The disadvantages include higher power consumption and residual
stress, lower geometrical accuracy and thickness of cladding. This report investigates the combination of the both
feedstock made from Inconel 718 to obtain higher build rates, deposition efficiency and lower distortions while
maintaining geometrical accuracy. Simulations for bilayer powder and wire feedstock laser deposition alone and
the combination of wire and powder laser deposition with comparable simulation parameters were conducted. The
differences in the deposition efficiency, thickness of cladding, transient temperature distribution and distortions
were assessed and discussed. The results confirmed that the hybrid powder and wire feed laser deposition process
contained benefits from both the deposition methods while reducing the drawbacks from previous additive
manufacturing processes.

Graphical Abstract:

1. Simulation for various scan patterns with powder direct energy deposition with comparable simulation
parameters such as finish time, print speed, deposition length and laser powder:
a) Bi-directional Pattern b) Out-to-In Pattern c) Fractal Curves
 B.Tech. Projects
Department of Mechanical Engineering,
Indian Institute of Technology Dharwad, KA, INDIA
2018 Batch

2. Experimental validation for the scanning strategies using Inconel 718 as the deposition material in powder
form and SS316 plates as the substrate while measuring residual stress at locations of interest and
temperature:
a) Bi-directional Pattern b) Out-to-In Pattern c) Fractal Curves

3. Simulations and comparison of characteristics for Bi-layer powder deposition, Bi-layer wire deposition
and hybrid wire and powder direct energy deposition. The results from the three simulations were
compared with the following parameters: Deposition efficiency, geometrical accuracy, cladding
thickness, transient temperature distribution, laser power and distortion.
a) Bilayer Powder DED b) Bi-layer Wire DED

c) Hybrid Wire and Powder DED

References:

[1] Syed, W. U., Pinkerton, A. J., & Li, L. (2006). “Simultaneous wire- and powder-feed direct metal
deposition: An investigation of the process characteristics and comparison with single-feed
methods.”
[2] Sun, L., Ren, X., He, J., & Zhang, Z. (2021). “Numerical investigation of a novel pattern for
reducing residual stress in metal additive manufacturing.”