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<p>Process parameters, such as wire feed rate, deposition travel speed and energy input per unit length, have a direct impact on controlling the dimensional consistency of the multi-layer components in the gas metal arc directed energy deposition (GMA-DED) process. The present investigation proposes a novel analytical methodology to estimate the build profile of single-track-multi-layer builds following mechanistic principles of energy balance and thermo-physical properties of the materials. The analytically estimated and the corresponding experimentally measured results for a range of process conditions considered in the present study have shown a fair agreement with a deviation of around 0.87%, 3.9% and 4% for build height, net build width and surface waviness, respectively. The present methodology can be employed to design the optimum process parameters for enhancing the reliability of GMA-DED components.</p>

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Analytical Estimation of Build Profile in Gas Metal Arc Directed Energy Deposition Process

  • 期刊论文

  • 发表日期：

    2025年8月20日

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  • Pratyush Jyoti Roy,
  • Aritra Karar,
  • Atanu Das

摘要

Process parameters, such as wire feed rate, deposition travel speed and energy input per unit length, have a direct impact on controlling the dimensional consistency of the multi-layer components in the gas metal arc directed energy deposition (GMA-DED) process. The present investigation proposes a novel analytical methodology to estimate the build profile of single-track-multi-layer builds following mechanistic principles of energy balance and thermo-physical properties of the materials. The analytically estimated and the corresponding experimentally measured results for a range of process conditions considered in the present study have shown a fair agreement with a deviation of around 0.87%, 3.9% and 4% for build height, net build width and surface waviness, respectively. The present methodology can be employed to design the optimum process parameters for enhancing the reliability of GMA-DED components.