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<p>This study investigates the influence of powder addition on bead geometry in wire-fed laser-directed energy deposition (L-DED). Single-layer-single-track (SLST) experiments are conducted using SS316L powder and IN718 wire feedstock, varying laser power, scan speed, and powder feed rate to understand their coupled effects on bead geometry. Powder addition with moderate feed rates is found to improve bead uniformity for SLST specimens printed with low linear energy density. It also increases the bead size as more material is deposited and extends the process window as the deposition of powder feedstock mitigates track nonuniformity. Further experiments are performed with single-layer-multi-track (SLMT) and multi-layer-multi-track (MLMT) configurations. In SLMT configurations, bead height is primarily governed by powder feed rate, bead width by hatch spacing, and inter-track valley formation by their combined effect. Stable MLMT builds are achieved, demonstrating that balling can be avoided by limiting excessive energy input and selecting appropriate nominal layer heights. A quantitative approach, suggesting appropriate nominal layer height using data drawn from the corresponding SLMT beads, is further proposed. Overall, this work demonstrates the role of powder as an effective process parameter in expanding operational envelopes and tailoring bead geometry in wire-fed L-DED.</p>

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Tailoring bead geometry through coaxial powder feeding in wire-based laser-directed energy deposition

  • 期刊论文

  • 发表日期：

    2026年1月8日

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  • Abdul Malik Al Mardhouf Al Saadi,
  • Kun-Hao Huang,
  • Amrita Basak

摘要

This study investigates the influence of powder addition on bead geometry in wire-fed laser-directed energy deposition (L-DED). Single-layer-single-track (SLST) experiments are conducted using SS316L powder and IN718 wire feedstock, varying laser power, scan speed, and powder feed rate to understand their coupled effects on bead geometry. Powder addition with moderate feed rates is found to improve bead uniformity for SLST specimens printed with low linear energy density. It also increases the bead size as more material is deposited and extends the process window as the deposition of powder feedstock mitigates track nonuniformity. Further experiments are performed with single-layer-multi-track (SLMT) and multi-layer-multi-track (MLMT) configurations. In SLMT configurations, bead height is primarily governed by powder feed rate, bead width by hatch spacing, and inter-track valley formation by their combined effect. Stable MLMT builds are achieved, demonstrating that balling can be avoided by limiting excessive energy input and selecting appropriate nominal layer heights. A quantitative approach, suggesting appropriate nominal layer height using data drawn from the corresponding SLMT beads, is further proposed. Overall, this work demonstrates the role of powder as an effective process parameter in expanding operational envelopes and tailoring bead geometry in wire-fed L-DED.