Feedstock Material Efficiency Analysis in Laser-based Directed Energy Deposition

Abstract

Feedstock material efficiency plays a crucial role in efficient and cost-effective directed energy deposition. This thesis examines the different process parameters in DED-LB/P relating to powder catchment efficiency and the methods used to determine it. The literature review presents common additive manufacturing processes, processing parameters, powder properties and powder catchment efficiency. In this study melt pool diameter and particle stream diameter are found to be the main factors in catchment efficiency. It is found that these factors can be altered and in turn catchment can be improved by changing powder size, laser spot size and carrier gas flow rate. Few relatively accurate methods used to determine and predict catchment efficiency are discussed in this study.