TY - JOUR

T1 - Combining wire and coaxial powder feeding in laser direct metal deposition for rapid prototyping

AU - Syed, Waheed Ul Haq

AU - Pinkerton, Andrew J.

AU - Li, L.

N1 - The final, definitive version of this article has been published in the Journal, Applied Surface Science, 252 (13), 2006, © ELSEVIER.

PY - 2006/4/30

Y1 - 2006/4/30

N2 - Powder and wire deposition have been used separately in many laser-cladding, rapid prototyping and other additive manufacturing applications. In this paper, a new approach is investigated by simultaneously feeding powder from a coaxial nozzle and wire from an off-axis nozzle into the deposition melt pool. Multilayer parts are built from 316L steel using a 1.5 kW diode laser and different configurations of the powder and wire nozzles are compared in terms of surface roughness, deposition rate, porosity and microstructure. The parts are analysed using scanning electron microscopy (SEM), X-ray diffraction (XRD) and optical microscopy techniques. Results show that deposition efficiency increased and surface roughness decreased with the combined process; some porosity was present in samples produced by this method, but it was 20-30% less than in samples produced by powder alone. Wire injection angles into the melt pool in both horizontal and vertical planes were found to be significant for attaining high deposition efficiency and good surface quality. Reasons for the final sample characteristics and differences between the combined process and the separate powder and wire feeding techniques are discussed. (c) 2005 Elsevier B.V. All rights reserved.

AB - Powder and wire deposition have been used separately in many laser-cladding, rapid prototyping and other additive manufacturing applications. In this paper, a new approach is investigated by simultaneously feeding powder from a coaxial nozzle and wire from an off-axis nozzle into the deposition melt pool. Multilayer parts are built from 316L steel using a 1.5 kW diode laser and different configurations of the powder and wire nozzles are compared in terms of surface roughness, deposition rate, porosity and microstructure. The parts are analysed using scanning electron microscopy (SEM), X-ray diffraction (XRD) and optical microscopy techniques. Results show that deposition efficiency increased and surface roughness decreased with the combined process; some porosity was present in samples produced by this method, but it was 20-30% less than in samples produced by powder alone. Wire injection angles into the melt pool in both horizontal and vertical planes were found to be significant for attaining high deposition efficiency and good surface quality. Reasons for the final sample characteristics and differences between the combined process and the separate powder and wire feeding techniques are discussed. (c) 2005 Elsevier B.V. All rights reserved.

KW - Coaxial powder feeding

KW - Wire feeding

KW - Diode laser

KW - Direct metal deposition

U2 - 10.1016/j.apsusc.2005.08.118

DO - 10.1016/j.apsusc.2005.08.118

M3 - Journal article

VL - 252

SP - 4803

EP - 4808

JO - Applied Surface Science

JF - Applied Surface Science

SN - 0169-4332

IS - 13

ER -