High efficiency molding by real-time control of distance between nozzle and melt pool in directed energy deposition process

Kengo Aizawa, Masahiro Ueda, Teppei Shimada, Hideki Aoyama, Kazuo Yamazaki

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Abstract

Laser metal deposition (LMD) is an additive manufacturing technique, whose performance can be influenced by a considerable number of factors and parameters. Typically, a powder is carried by an inert gas and sprayed by a nozzle, with a coaxial laser beam passing through the nozzle and overlapping the powder flow, thereby generating a molten material pool on a substrate. Monitoring the evolution of this process allows for a better comprehension and control of the process, thereby enhancing the deposition quality. As the metal additive manufacturing mechanism has not yet been elucidated, it is not clear how process parameters affect material properties, molding accuracy, and molding efficiency. When cladding is performed under uncertain conditions, a molded part with poor material properties and dimensional accuracy is created. In this paper, we propose a method for high efficiency molding by controlling the distance between the head nozzle and the molten pool in real time. The distance is identified by an originally developed sensor based on a triangulation method. According to the distance, the head nozzle is automatically controlled into the optimum position. As a result, an ideal molding process can be generated, so that high efficiency molding and high-quality material properties can be obtained. Experimental results show that continuing deposition at the optimum distance assists in achieving deposition efficiency and dimensional accuracy. According to the specific experimental results of this method, the modeling efficiency was increased by 27% compared to the method without correction, and the modeling was successful with an error within 1 mm.

Original languageEnglish
Title of host publicationJSME 2020 Conference on Leading Edge Manufacturing/Materials and Processing, LEMP 2020
PublisherAmerican Society of Mechanical Engineers
ISBN (Electronic)9780791883624
DOIs
Publication statusPublished - 2020
EventJSME 2020 Conference on Leading Edge Manufacturing/Materials and Processing, LEMP 2020 - Virtual, Online
Duration: 2020 Sep 3 → …

Publication series

NameJSME 2020 Conference on Leading Edge Manufacturing/Materials and Processing, LEMP 2020

Conference

ConferenceJSME 2020 Conference on Leading Edge Manufacturing/Materials and Processing, LEMP 2020
CityVirtual, Online
Period20/9/3 → …

ASJC Scopus subject areas

  • Industrial and Manufacturing Engineering
  • Mechanical Engineering
  • Mechanics of Materials
  • Materials Science (miscellaneous)
  • Instrumentation

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