Utilizing intermediate feature value correlation for efficient parameter identification in high-speed directed energy deposition

Powder-based high-speed directed energy deposition with laser beam (HS DED-LB) is a key enabler for circular and resource-efficient manufacturing, combining high deposition velocities up to 200 m/min and layer heights down to 50 μm. However, determining suitable process parameters based on conventional ex-situ analyses remains time-consuming and cost-intensive. This explorative study employs an in-between extraction method to determine intermediate feature values of two-layer samples. To characterize the properties of the two-layer samples surface texture measurements and hardness measurements were performed. The feature values were then correlated with key quality metrics, specifically porosity and hardness. The findings demonstrate that surface texture parameters, when used as intermediate feature values, can serve as indicators of the final component density, enabling faster and more cost-efficient process parameter identification. In particular, the correlation between surface-level feature data and subsurface defects highlights the potential of surface-based monitoring as an effective means of assessing component quality. This contributes to more reliable and functionally robust components in high-performance applications and broadens the applicability of HS DED-LB in circular production environments.