Integrated analysis of energy-process parameters relationship in direct energy deposition of 15–5 PH stainless steel

Direct Energy Deposition (DED) is a widely used method for rapid prototyping, particularly for making dense metal parts, despite its notable energy requirements. This paper presents a novel mathematical modeling method that links important process variables to energy consumption in Directed Energy Deposition (DED). The research explores the impact DED process parameters like laser power, scan speed, and powder feed rate on clad geometry and microstructure by depositing 15–5 precipitation-hardened stainless steel onto a 304L stainless steel substrate through a single-track technique experiment. The results shows the relationship between process parameters and energy use, offering guidance for improving production costs and time efficiency. Within the 200–350 W range, laser power is crucial for maintaining clad height stability, while scan speed impacts clad depth and powder feed rate influences clad width. Precise parameter management is crucial for maintaining constant clad dimensions and enhancing part quality in DED manufacturing. Four-Dimensional X-ray Microscopy (FDXM) is used to examine porosities and flaws in the deposited layer, providing insights into the melting behavior of metal powder.