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<p>The build angles referred to as the wire feed angle (<i>α</i>) and substrate angle (<i>θ</i>) in additive manufacturing (AM), are essential for defining the multi-axis tool path and characteristics of bead geometry. This work fundamentally explores the influence of build angles on process physics, focusing on the bead peak shift and aspect ratio, to better understand laser-material interaction phenomena in the robotic non-planar laser-wire directed energy deposition (LWDED) process. The bead peak shift and aspect ratio are introduced for the first time in the context of optimizing build angles. A model based on laser-wire interaction (LWI) and incident angle for absorbed laser energy density has been introduced. The optimum build angles reveal that the wire feed angles are more significant in achieving improved results with an absolute error of 8.4% and 13.99% for the predicted aspect ratio and peak shift, respectively. The relationship between laser energy absorption and laser wire interaction volume has been developed. The optimized samples were tested for adhesion, scratch hardness, and microhardness. At an indentation load of 20&#xa0;N, scratch hardness and microhardness strongly correlated for the optimum build angle sets. A non-circular laser beam shape, LWI time and pulsed laser influenced the characteristics of the bead during the non-planar LWDED process. These results help to achieve the required bead quality by deciding the build angles to facilitate automation in the LWDED process.</p>

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Influence of build angles on layer characteristics at non-planar orientations during robot-assisted laser-wire DED

  • 期刊论文

  • 发表日期：

    2025年6月2日

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  • Sumitkumar Rathor,
  • Ravi Kant,
  • Ekta Singla,
  • Dhruva Kumar Goyal

摘要

The build angles referred to as the wire feed angle (α) and substrate angle (θ) in additive manufacturing (AM), are essential for defining the multi-axis tool path and characteristics of bead geometry. This work fundamentally explores the influence of build angles on process physics, focusing on the bead peak shift and aspect ratio, to better understand laser-material interaction phenomena in the robotic non-planar laser-wire directed energy deposition (LWDED) process. The bead peak shift and aspect ratio are introduced for the first time in the context of optimizing build angles. A model based on laser-wire interaction (LWI) and incident angle for absorbed laser energy density has been introduced. The optimum build angles reveal that the wire feed angles are more significant in achieving improved results with an absolute error of 8.4% and 13.99% for the predicted aspect ratio and peak shift, respectively. The relationship between laser energy absorption and laser wire interaction volume has been developed. The optimized samples were tested for adhesion, scratch hardness, and microhardness. At an indentation load of 20 N, scratch hardness and microhardness strongly correlated for the optimum build angle sets. A non-circular laser beam shape, LWI time and pulsed laser influenced the characteristics of the bead during the non-planar LWDED process. These results help to achieve the required bead quality by deciding the build angles to facilitate automation in the LWDED process.