Influence of Particle Size Distribution in High-Speed Directed Energy Deposition

Powder-based high-speed directed energy deposition using a laser beam (HS DED-LB) is a novel variation of directed energy deposition (DED-LB). By shifting the powder focus above the substrate, the added powder is melted prior to deposition, allowing processing speeds of up to 200 m/min. Modern HS DED-LB systems include 5-axis capabilities, allowing material to be applied to irregular geometries, making the process particularly suitable for re-manufacturing. As a result, the process has great potential for the industry. In-creased material and energy efficiency throughout the process chain is essential to improve process efficiency. By enabling coarser particle size distributions for HS DED-LB, both the economic efficiency can be increased and the reconditioning losses can be reduced. The aim of this study is to show the interaction between powder-gas flow, process parameters and the resulting weld track.