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<p>Direct laser metal deposition is a versatile additive manufacturing technique known for its ability to fabricate complex geometries with high precision. However, the thermal history during deposition can significantly influence the microstructure, distortions, and mechanical properties of the final product. This study investigates the influence of scanning path strategies, namely linear bidirectional (conventional), flattened trochoidal (fully circular), and adaptive trochoidal (semi-circular), on the thermal dynamics and resulting material characteristics in direct laser metal deposition (DLMD) of Ti-6Al-4V alloy. Using infrared thermal imaging, detailed comparisons were made of the thermal history, cooling rates, and spatial heat distribution at different scan speeds (100, 250, and 400&#xa0;mm/min). Results revealed that the adaptive trochoidal path produced the most thermally balanced behaviour, with up to 18% lower peak temperatures and 25–30% lower temperature fluctuation range compared to the linear bidirectional strategy. Cooling rate analysis showed that adaptive trochoidal scanning maintained a more gradual cooling slope, especially at the middle point. Microstructural examination confirmed a finer grain structure in trochoidal paths, particularly adaptive ones, correlating with a 10–15% increase in microhardness compared to linear scanning. The study highlights how path shape optimization can significantly improve thermal management and enhance mechanical performance in DLMD applications, providing valuable insights for the design of complex geometries in additive manufacturing.</p>

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Thermal dynamics in direct laser metal deposition of Ti-6Al-4V: comparative study of linear and trochoidal path strategies

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年5月4日

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  • Abdul Hamid Ahmad,
  • Mohd Azlan Suhaimi,
  • Jailani Jamaludin,
  • Safian Sharif

摘要

Direct laser metal deposition is a versatile additive manufacturing technique known for its ability to fabricate complex geometries with high precision. However, the thermal history during deposition can significantly influence the microstructure, distortions, and mechanical properties of the final product. This study investigates the influence of scanning path strategies, namely linear bidirectional (conventional), flattened trochoidal (fully circular), and adaptive trochoidal (semi-circular), on the thermal dynamics and resulting material characteristics in direct laser metal deposition (DLMD) of Ti-6Al-4V alloy. Using infrared thermal imaging, detailed comparisons were made of the thermal history, cooling rates, and spatial heat distribution at different scan speeds (100, 250, and 400 mm/min). Results revealed that the adaptive trochoidal path produced the most thermally balanced behaviour, with up to 18% lower peak temperatures and 25–30% lower temperature fluctuation range compared to the linear bidirectional strategy. Cooling rate analysis showed that adaptive trochoidal scanning maintained a more gradual cooling slope, especially at the middle point. Microstructural examination confirmed a finer grain structure in trochoidal paths, particularly adaptive ones, correlating with a 10–15% increase in microhardness compared to linear scanning. The study highlights how path shape optimization can significantly improve thermal management and enhance mechanical performance in DLMD applications, providing valuable insights for the design of complex geometries in additive manufacturing.