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<p>A response surface methodology (RSM) is proposed as a systematic approach for developing process parameters for laser powder-directed energy deposition (LP-DED) C103. This work examines weld bead diameter as the primary response variable, as it offers a more accessible measurement compared to the conventional relative density approach. A quadratic model was developed using a Box-Behnken design to predict weld bead size as a function of laser power, scanning speed, and mass flow rate. The model achieved an <i>R</i><sup>2</sup> of 79 pct and yielded an optimal parameter set with corresponding to a relative density of 99.997&#xa0;pct. Printed samples were subjected to a vacuum stress relief heat treatment cycle prior to final machining according to standard ASTM E8 dimensions. Tensile testing of samples along the build direction resulted in ultimate tensile strength (UTS), yield strength (YS), and elongation percentage (pct <i>E</i>) values of 457, 376 MPa, and 24.37 pct, respectively. Meanwhile, specimens loaded perpendicular to the build direction resulted in UTS, YS, and pct <i>E</i> of 424, 312 MPa, and 32.15 pct, respectively. Investigation of the fracture surfaces revealed that the fracture propagated mainly along the grain boundaries.</p>

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Response Surface Methodology for Parameter Development & Mechanical Testing of Laser Powder-Directed Energy Deposition C103

  • 期刊论文

  • 发表日期：

    2025年7月22日

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  • Brandon J. Colón,
  • Noah Philips,
  • Francisco Medina

摘要

A response surface methodology (RSM) is proposed as a systematic approach for developing process parameters for laser powder-directed energy deposition (LP-DED) C103. This work examines weld bead diameter as the primary response variable, as it offers a more accessible measurement compared to the conventional relative density approach. A quadratic model was developed using a Box-Behnken design to predict weld bead size as a function of laser power, scanning speed, and mass flow rate. The model achieved an R2 of 79 pct and yielded an optimal parameter set with corresponding to a relative density of 99.997 pct. Printed samples were subjected to a vacuum stress relief heat treatment cycle prior to final machining according to standard ASTM E8 dimensions. Tensile testing of samples along the build direction resulted in ultimate tensile strength (UTS), yield strength (YS), and elongation percentage (pct E) values of 457, 376 MPa, and 24.37 pct, respectively. Meanwhile, specimens loaded perpendicular to the build direction resulted in UTS, YS, and pct E of 424, 312 MPa, and 32.15 pct, respectively. Investigation of the fracture surfaces revealed that the fracture propagated mainly along the grain boundaries.