Burl Alan, Hussein Zaky, Adapa Venkata Surya Karthik, Foley Melissa, Handel Nicole Van, McCoy Matthew, Kurfess Thomas, Saldaña Christopher, Saleeby Kyle
GW Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA USA.
Georgia Tech Manufacturing Institute, Georgia Institute of Technology, Atlanta, GA USA.
NPJ Adv Manuf. 2025;2(1):38. doi: 10.1038/s44334-025-00034-z. Epub 2025 Aug 29.
As multiple macro scale directed energy deposition (DED) processes begin to be industrially adopted for large scale component manufacture, it is imperative that interface strategies between the processes are fully understood. The present work investigates the asynchronous deposition of a wire component (DED-arc), followed by a powder-based deposition (DED-LP) with varying surface treatments which were evaluated for flatness, porosity, hardness, and Charpy impact energy. The self-regulation effect of DED-LP was fully realized with up to 55% reduction in surface variation relative to the DED-arc surface. Contrarily, as surface contaminants were not removed between each process, the resultant DED-LP porosity was significantly reduced from 99.5% to 92.4%. Albeit the reduction in density did not negatively impact the impact toughness as evidenced by a low correlation coefficient of -0.46. As such, the overall manufacturing costs and application space must be considered for selection of the different interface strategies presented in the current work.
随着多种宏观尺度的定向能量沉积（DED）工艺开始在工业上用于大规模零部件制造，全面理解这些工艺之间的界面策略至关重要。目前的工作研究了先进行丝状部件的异步沉积（DED-电弧），随后进行基于粉末的沉积（DED-LP），并对不同的表面处理进行了评估，包括平整度、孔隙率、硬度和夏比冲击能量。DED-LP的自调节效应得到充分体现，相对于DED-电弧表面，表面变化减少了高达55%。相反，由于在每个工艺之间未去除表面污染物，最终的DED-LP孔隙率从99.5%显著降低至92.4%。尽管密度降低，但冲击韧性并未受到负面影响，相关系数低至-0.46即可证明。因此，在选择当前工作中提出的不同界面策略时，必须考虑总体制造成本和应用空间。
