High-Speed DED-LB: Analysis of Process Control Variables as Enabler for Remanufacturing of Unique Products

The implementation of sustainable production patterns in the sense of a circular economy is becoming increasingly important due to the rising consumption of resources. In addition, remanufacturing enables the technological sovereignty of company locations. The aim of remanufacturing is to return used products to the market in an as-new or even better condition than initial new products. To achieve this, flexible, semi-autonomous production is needed, which requires a coordinated, adaptable production system. This can be achieved by combining additive manufacturing (AM) and machining. Powder-based high-speed directed energy deposition using a laser beam (DED-LB) is particularly suitable for this application. High-speed DED-LB enables multifunctional structures and the combination of multiple metal powders in a single component. In addition, by specifically influencing the cooling rates, high-speed DED-LB is capable of producing metal parts with high hardness and high strength. Modern DED-LB systems include 5-axis features, allowing material to be applied to irregular geometries. To unlock the full potential of the DED-LB process, suitable process parameters for thick- and thin-walled components must be derived. ... mehrTherefore, the relationship between process parameters, resulting geometries and process influences on microstructure must be known. This will help to overcome technical challenges such as repeatability and quality, as well as difficulties caused by cumulative defects, and create a basis for reliable reprocessing in the sense of a circular economy.