Effect of laser energy density on bead characteristics in wire-DED

Achieving repeatability in part production remains a challenge in laser-wire feed directed energy deposition (LW-DED). It is necessary to understand the laser-wire deposition and bead aspect ratio varying the process conditions to achieve repeatability. Laser energy density is one of the key process parameters that affect the dimensions of the deposit. So, this study discusses the fundamentals of depositing the copper-coated ER70S-6 low carbon steel wire. The laser energy density effects on aspect ratio, overall porosity, microstructure, and microhardness are presented. The bead morphology changes with the change in laser energy density. Single track deposited sample results helped in understanding the melt transition for material deposition and dimensional resolution of the deposited track.