• Journal of the Korean Society of Manufacturing Process Engineers
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• v.20 no.6
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• pp.59-69
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• 2021

Directed energy deposition (DED) is an additive manufacturing technology involving a focused high-power laser or electron beam propagating over the substrate, resulting in melt pool formation while simultaneously supplying metal powder to the melt pool area to deposit the material. DED is performed to repair and strengthen parts in various applications, as it can be easily integrate local area cladding and cross-material deposition. In this study, we characterize stainless steel 316 L parts fabricated via DED based on various deposition conditions and geometries to widen the application of DED. The deposition characteristics are investigated by varying the laser power and powder feed rate. Multilayer deposition with a laser power of 362 W and a powder feed rate of 6.61 g/min indicate a height closest to the design value while affording high surface quality. The microhardness of the specimen increases from the top to the bottom of the deposited area. Tensile tests of specimens with two different deposition directions indicate that horizontally long specimens with respect to a substrate demonstrate a higher ultimate tensile strength and yield strength than vertically long specimens with lower elongation.

• Journal of the Korean Society of Industry Convergence
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• v.25 no.6_1
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• pp.941-952
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• 2022

In this study, additive manufacturing technology was applied to restore a planner miller that was unusable due to aging. The drive spur gear of the planner miller was inoperable due to many defects in the teeth. The shape of the defective gear teeth was restored by deposition of the defective teeth using the DED method. However, as the location of the deposition head and the location of the set origin became farther, the deposition shape was different from the modeling shape. Nonetheless, since the modeling of the deposition part was designed to be larger than the tooth shape of the original gear, it was possible to completely restore all gear teeth through post-processing. The arrangement interval of the flow lines of the deposition part was narrower than that of the substrate. The hardness of the substrate was 172 HV, and that of the deposition part was 345 HV, which was twice as high as that of the substrate.

• Journal of the Korean Society of Industry Convergence
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• v.25 no.4_2
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• pp.699-706
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• 2022

In this study, Directed energy deposition (DED) among additive manufacturing is applied to repair damaged spindle key parts of planner miller. The material of the spindle key is SCM415, and the P21 Powder is used. In order to find the optimal deposition conditions for DED equipment, a single-line deposition experiment is conducted to analysis five parameters. The laser power affects the width, and the height is a parameter affected by coaxial gas and powder gas. In addition, laser power, powder feed rate, coaxial gas, and powder gas are parameters that affect dilution. Otimal deposition is that 400 W of laser power, 4.0 g/min of powder feed rate, 6.5 L/min of coaxial gas, 3.0 L/min of powder gas and 4.5 L/min of shield gas. By setting the optimum conditions, a uniform deposition cross section in the form of an ellipse can be obtained. Damage recovery process of spindle key consists of 3D shape design of the base and deposition parts, deposition path creation and deposition process, and post-processing. The hardness of deposited area with P21 powder on the SCM415 spindle key is 336 HV for the surface of the deposition, 260 HV for the boundary area, and 165 HV for the base material.

• Transactions of Materials Processing
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• v.30 no.3
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• pp.109-118
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• 2021

Recently, there has been an increased interest in the remanufacturing of mechanical parts using metal additive manufacturing processes in regards to resource recycling and carbon neutrality. DED (directed energy deposition) process can create desired metallic shapes on both even and uneven substrate via line-by-line deposition. Hence, DED process is very useful for the repair, retrofit and remanufacturing of mechanical parts with irregular damages. The objective of the current paper is to investigate the effects DED process parameters, including the effects of power and the scan speed of the laser, on deposition and residual stress characteristics for remanufacturing of mechanical parts using experiments and finite element analyses (FEAs). AISI 1045 is used as the substrate material and the feeding powder. The characteristic dimensions of the bead shape and the heat affected zone (HAZ) for different deposition conditions are obtained from the experimental results. Efficiencies of the heat flux model for different deposition conditions are estimated by the comparison of the results of FEAs with those of experiments in terms of the width and the depth of HAZ. In addition, the influence of the process parameters on residual stress distributions in the vicinity of the deposited region is investigated using the results of FEAs. Finally, a suitable deposition condition is predicted in regards to the bead formation and the residual stress.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.21 no.6
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• pp.50-59
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• 2022

The design of the substrate significantly affects the thermal history and the residual stress formation in the vicinity of a repaired region by a directed energy deposition (DED) process. The occurrence of defects in the repaired region depends on the thermal history and residual stress formation. The objective of this study was to investigate the influence of the inclined angle and depth of the substrate on the thermal and residual stress characteristics in the vicinity of a repaired region by a DED process through two-dimensional finite element analyses (FEAs). The temperature and residual stress distributions in the vicinity of the repaired region were predicted according to the combination of the inclined angle and depth of the substrate. The effects of the inclined angle and depth on the depth of the heat affected zone and the maximum value of the residual stress were examined. A proper combination of the inclined angle and depth of the substrate was estimated to decrease the residual stress in the vicinity of the repaired region.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.20 no.10
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• pp.27-37
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• 2021

The use of additive manufacturing processes for the repair and remanufacturing of mechanical parts has attracted considerable attention because of strict environmental regulations. Directed energy deposition (DED) is widely used to retrofit mechanical parts. In this study, finite element analyses (FEAs) were performed to investigate the influence of the substrate phase and inclination angle on the heat transfer characteristics in the vicinity of Hastelloy X regions deposited via DED. FE models that consider the bead size and hatch distance were designed. A volumetric heat source model with a Gaussian distribution in a plane was adopted as the heat flux model for DED. The substrate and the deposited powder were S45C structural steel and Hastelloy X, respectively. Temperature-dependent thermal properties were considered while performing the FEAs. The effects of the substrate phase and inclination angle on the temperature distributions and depth of the heat-affected zone (HAZ) in the vicinity of the deposited regions were examined. Furthermore, the influence of deposition paths on depths of the HAZ were investigated. The results of the analyses were used to determine the suitable phase and inclination angle of the substrate as well as the appropriate deposition path.

• Journal of Powder Materials
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• v.28 no.6
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• pp.491-496
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• 2021

The process optimization of directed energy deposition (DED) has become imperative in the manufacture of reliable products. However, an energy-density-based approach without a sufficient powder feed rate hinders the attainment of an appropriate processing window for DED-processed materials. Optimizing the processing of DED-processed Ti-6Al- 4V alloys using energy per unit area (E_eff) and powder deposition density (PDD_eff) as parameters helps overcome this problem in the present work. The experimental results show a lack of fusion, complete melting, and overmelting regions, which can be differentiated using energy per unit mass as a measure. Moreover, the optimized processing window (E_eff = 44~47 J/mm² and PDD_eff = 0.002~0.0025 g/mm²) is located within the complete melting region. This result shows that the Eeff and PDDeff-based processing optimization methodology is effective for estimating the properties of DED-processed materials.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.20 no.7
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• pp.33-40
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• 2021

Current industrial flow is directed toward reducing the usage of raw materials by reusing parts, which is referred to as a circular economy (CE). Repair is one of the most value-added approaches in CE, which can be efficiently accomplished via additive manufacturing. The repair technology of metallic parts via the directed energy deposition process, which includes the selective removal and redeposition of damaged regions of metallic parts. Residual stress characteristics depend on the shape of the part and the shape of the redeposition region. The objective of this study is to investigate the effects of the radius and corner position of the substrate on the residual stresses for repair by using finite element analysis (FEA). The residual stress distribution of the 45° angle groove at the edge of the circular shape models on the outer and inner radii was analytically investigated. The analysis was accomplished using SYSWELD software by applying a moving heat source with defined material properties and cooling conditions integrated into the FEA model. The results showed a similar pattern of concentrated stress distribution for all models except the 40-mm and 60-mm radii, for which the maximum stress locations were different. The maximum residual stresses are high but lower than the yield strength, suggesting the absence of cracks and fractures due to residual stresses.

• Proceedings of the Materials Research Society of Korea Conference
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• 2011.05a
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• pp.239.1-239.1
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• 2011

Dye sensitized solar cells (DSC) are promising devices for inexpensive, nontoxic, transparent, and large-scale solar energy conversion. Generally thick $TiO_2$ nanoporous films act as efficient photoanodes with their large surface area for absorbing light. However, electron transport through nanoparticle networks causes the slowdown and the loss of electron transport because of a number of interparticle boundaries inside the conduction path. We have studied DSCs with precisely dimension-controlled $TiO_2$ nanotubes array as photoanode. $TiO_2$ nanotubes array is prepared by template-directed fabrication method with atomic layer deposition. Well-ordered nanotubes array provides not only large surface area for light absorbing but also direct pathway for electrons with minimalized grain boundaries. Large enlongated anatase grains in the nanotubes could enhance the conductivity of electrons, but also suppress the recombination with holes through defect sites during diffusion into the electrode. To study the effect of grain boundaries, we fabricated two kinds of nanotubes which have different grain sizes by controlling deposition conditions. And we studied electron conduction through two kinds of nanotubes with different grain structures. The solar cell performance was studied as a function of thickness and grain structures. And overall solar-to-electric energy conversion efficiencies of up to 7% were obtained.

• Journal of Powder Materials
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• v.27 no.3
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• pp.219-225
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• 2020

The directed energy deposition (DED) process of metal 3D printing technologies has been treated as an effective method for welding, repairing, and even 3-dimensional building of machinery parts. In this study, stainless steel 316L (STS316L) and Inconel 625 (IN625) alloy powders are additively manufactured using the DED process, and the microstructure of the fabricated STS316L/IN625 sample is investigated. In particular, there are no secondary phases in the interface between STS316L and the IN625 alloy. The EDS and Vickers hardness results clearly show compositionally and mechanically transient layers a few tens of micrometers in thickness. Interestingly, several cracks are only observed in the STS 316L rather than in the IN625 alloy near the interface. In addition, small-sized voids 200-400 nm in diameter that look like trapped pores are present in both materials. The cracks present near the interface are formed by tensile stress in STS316L caused by the difference in the CTE (coefficient of thermal expansion) between the two materials during the DED process. These results can provide fundamental information for the fabrication of machinery parts that require joining of two materials, such as valves.