Understanding the capture efficiency of powder during direct laser deposition (DLD) is critical when determining the overall manufacturing costs of additive manufacturing (AM) for comparison to traditional manufacturing methods. By developing a tool to predict the capture efficiency of a particular deposition process, parameter optimization can be achieved without the need to perform a costly and extensive experimental study. The focus of this work is to model the deposition process and acquire the final track geometry and temperature field of a single track deposition of Ti–6Al–4V powder on a Ti–6Al–4V substrate for a four-nozzle powder delivery system during direct laser deposition with a LENS™ system without the need for capture efficiency assumptions by using physical powder flow and laser irradiation profiles to predict capture efficiency. The model was able to predict the track height and width within 2 μm and 31 μm, respectively, or 3.3% error from experimentation. A maximum of 36 μm profile error was observed in the molten pool, and corresponds to errors of 11% and 4% in molten pool depth and width, respectively. Based on experimentation, the capture efficiency of a single track deposition of Ti–6Al–4V was found to be 12.0%, while that from simulation was calculated to be 11.7%, a 2.5% deviation.
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January 2019
Research-Article
Self-Sufficient Modeling of Single Track Deposition of Ti–6Al–4V With the Prediction of Capture Efficiency
Christopher Katinas,
Christopher Katinas
School of Mechanical Engineering,
Purdue University,
West Lafayette, IN 47907
e-mail: ckatinas@purdue.edu
Purdue University,
West Lafayette, IN 47907
e-mail: ckatinas@purdue.edu
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Shunyu Liu,
Shunyu Liu
School of Mechanical Engineering,
Purdue University,
West Lafayette, IN 47907
e-mail: liu1760@purdue.edu
Purdue University,
West Lafayette, IN 47907
e-mail: liu1760@purdue.edu
Search for other works by this author on:
Yung C. Shin
Yung C. Shin
ASME Fellow
School of Mechanical Engineering,
Purdue University,
West Lafayette, IN 47907
e-mail: shin@purdue.edu
School of Mechanical Engineering,
Purdue University,
West Lafayette, IN 47907
e-mail: shin@purdue.edu
Search for other works by this author on:
Christopher Katinas
School of Mechanical Engineering,
Purdue University,
West Lafayette, IN 47907
e-mail: ckatinas@purdue.edu
Purdue University,
West Lafayette, IN 47907
e-mail: ckatinas@purdue.edu
Shunyu Liu
School of Mechanical Engineering,
Purdue University,
West Lafayette, IN 47907
e-mail: liu1760@purdue.edu
Purdue University,
West Lafayette, IN 47907
e-mail: liu1760@purdue.edu
Yung C. Shin
ASME Fellow
School of Mechanical Engineering,
Purdue University,
West Lafayette, IN 47907
e-mail: shin@purdue.edu
School of Mechanical Engineering,
Purdue University,
West Lafayette, IN 47907
e-mail: shin@purdue.edu
1Corresponding author.
Manuscript received April 6, 2018; final manuscript received August 27, 2018; published online October 8, 2018. Assoc. Editor: Zhijian (ZJ) Pei.
J. Manuf. Sci. Eng. Jan 2019, 141(1): 011001 (10 pages)
Published Online: October 8, 2018
Article history
Received:
April 6, 2018
Revised:
August 27, 2018
Citation
Katinas, C., Liu, S., and Shin, Y. C. (October 8, 2018). "Self-Sufficient Modeling of Single Track Deposition of Ti–6Al–4V With the Prediction of Capture Efficiency." ASME. J. Manuf. Sci. Eng. January 2019; 141(1): 011001. https://doi.org/10.1115/1.4041423
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