Investigation on layer variation behavior and process stability during direct laser deposition using a semi-theoretic analysis model

• Published in: Journal of manufacturing processes Vol. 75; pp. 1058 - 1071
• Main Authors: Bian, Qingfei, Li, Xinyi, Guo, Shaojie, He, Yu, Yao, Shouguang
• Format: Journal Article
• Language: English
• Published: Elsevier Ltd 01.03.2022
• Subjects: Direct laser deposition; Eccentricity; Nozzle arrangement; Process stability; Semi-theoretic analysis model; Semi-theoretic analysis model; Process stability; Eccentricity; Nozzle arrangement; Direct laser deposition
• ISSN: 1526-6125; 2212-4616
• DOI: 10.1016/j.jmapro.2022.01.049

For the promising direct laser deposition process, clarifying physical mechanism, optimizing manufacturing quality and realizing process stability and controllability are the current research hotspots to further improve and popularize this technology. However, under the limitation of complex physical processes, the research on the process stability is relatively insufficient. Especially for large scale study, it is affected by the across scales process, and it is rarely investigated in the previous literature due to the complicated methodology. Here, based on model reliability validation, a semi-theoretic analysis model considering main physical phenomena in the direct laser deposition process is established. The influence of the matching degree of working plane, powder deposition nozzle, and laser beam on the layer variation behavior and process stability during single-layer cladding is investigated. Results show that when the working plane, laser focal plane, and particle focal plane coincide, a largest cladding height can be obtained. Furthermore, the manufacturing efficiency and process stability are obviously improved by the effective adjustment of the matching degree of laser and particle nozzle, such as the eccentricity of the laser and particle center, and the axis-symmetrical nozzle arrangement, while they are reduced with the eccentricity and symmetry angle increasing and the direction angle deviation. •A semi-theoretic analysis model considering the main physical phenomena of direct laser deposition process is established.•Deviation sensitivity of laser focal plane increases with the increase of laser wavelength and the decrease of laser radius.•Laser and particle eccentricity formed against laser scan direction is beneficial for improving layer cladding efficiency.•Axis-symmetrical nozzle arrangement along laser scan direction improves the manufacturing efficiency and process stability.