Optimizing Direct Energy Deposition Process Parameters for Enhanced Print Reliability and Quality
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This study employed an iterative simulation approach, utilizing the finite element method, to optimize key DED process parameters, focusing on laser power optimization. Simple geometries were chosen with decreasing track lengths resulting in less cool down time between layers, leading to significant overheating. On these geometry’s, different laser power scaling methods were simulated and tested, with different interlayer temperature limits, in an effort to mitigate overheating. The geometries were built using the titanium Ti-6Al-4V alloy, a commonly used alloy in aerospace applications. Although the method works for all materials, as long as calibration is performed
