Powder Flow Analysis For Industrial Metallic Additive Manufacturing Directed Energy Deposition: Three Different Optical Approaches To Visualize The Powder Behavior

Authors:

Clovis Alleaume (AIMEN, Spain),
Pilar Rey Rodriguez (AIMEN, Spain),
Alejandro Lázaro Martínez (AIMEN, Spain),
Raúl Sanchez Cruz (AIMEN, Spain),
Camilo Prieto Río (AIMEN, Spain)

Abstract:

Powder characteristics are important factors affecting the quality of metallic Directed Energy Deposition (DED) process. To improve the DED reliability, we have studied the behaviour of the powder and the gas that are expelled from the laser head nozzle. In order to do so, three different optical setups have been developed and used, allowing us to visualize the particle distribution in space, to determinate the speed and trajectory of individual particles, and to visualize the gas behaviour interacting with those particles. Those setups were used while changing different process parameters: powder composition (metals, ceramic, and mixtures of those), mass flow (grams|min) and gas flows (carrier & protection). A series of experimentation have been performed to ensure independent and quantified changes of each parameter. The obtained results will be presented, and the implication on a theoretical tolerance roadmap for industrial application will be discussed.

DOI:

https://doi.org/10.59499/WP225370827