This project seeks to develop a knowledge base for Ti-6Al-4V powder that offers a matrix of vetted process parameters in order to obtain defect-free deposition in additive manufacturing utilizing the LENS® directed energy deposition (DED) process.
Optomec’s laser engineered net shaping (LENS) additive manufacturing (AM) process is governed by a large number of process parameters (e.g. power, wavelength, spot size, energy flux distribution, scanning velocity, powder feed rate, and substrate preheat). Various combinations of these parameters are being used today to produce AM components. There is currently no process parameter database, or knowledge base, to obtain defect-free AM deposition of Ti-6Al-4V utilizing the LENS powder fed directed energy deposition (DED) process.
The aim of this project is to develop a knowledge base for aerospace alloy Ti-6Al-4V in collaboration with Optomec, Applied Optimization, and the Pennsylvania State University—Applied Research Laboratory (ARL), offering a matrix of vetted process parameter combinations and best practices for LENS users. A knowledge base for Ti-6Al-4V would allow a process engineer to select from a matrix of vetted process parameter combinations which would minimize, and potentially eliminate, the trial and error approach to AM part process development.
Multiple AM builds of Ti-6Al-4V are being conducted to develop known parameters to yield optimal results that will be captured in an AM knowledge base. To populate the knowledge base, the team plans to:
- Define process parameter ranges
- Simulate deposition with varied parameters under single-line, multi-line, and multi-layer conditions
- Validate deposition via designed experiments under single-line, multi-line, and multi-layer conditions
- Repeat as required to refine correlation
- Populate the knowledge base
Other Project Participants
- Applied Optimization
- U.S. Department of Defense
- National Science Foundation
- U.S. Department of Energy