Review on surface characteristics of components produced by direct metal deposition process

Pratheesh Kumar S; Anand K; Hari Chealvan S; Karthikeya Muthu S

doi:10.15282/jmes.16.4.2022.05.0729

Authors

S. Pratheesh Kumar Department of Production Engineering, PSG College of Technology, Coimbatore, Tamil Nadu-641004, India. Phone: +91 9489227914; Fax.: 04222592277
K. Anand Department of Production Engineering, PSG College of Technology, Coimbatore, Tamil Nadu-641004, India. Phone: +91 9489227914; Fax.: 04222592277
S. Hari Chealvan Department of Production Engineering, PSG College of Technology, Coimbatore, Tamil Nadu-641004, India. Phone: +91 9489227914; Fax.: 04222592277
S. Karthikeya Muthu Department of Production Engineering, PSG College of Technology, Coimbatore, Tamil Nadu-641004, India. Phone: +91 9489227914; Fax.: 04222592277

DOI:

https://doi.org/10.15282/jmes.16.4.2022.05.0729

Keywords:

Additive manufacturing, Direct metal deposition, Surface characteristics, Surface roughness, Surface hardness

Abstract

Direct metal deposition (DMD) is a metal additive manufacturing (AM) process that builds objects layer by layer. The surface properties of DMD components are discussed in this study. The fluctuation of surface attributes such as roughness, finish, texture, and so on as a function of operation parameters has been investigated for a number of materials. This research assists in identifying the optimal process parameters for the material chosen, such as material feed rate, gas flow rate, and laser power, in order to generate the best surface characteristics. The results show that wire feed deposition surpasses powder feed deposition. The laser power and scanning speed of the laser were found to be the most influential process parameters. The study results reveal that the optimum process parameter combinations are material specific and is the keyfactor for obtaining better products with reduced surface roughness and waviness. The microstructural study also explores the material specfic effect in processs parameter combinations. This research could be used to determine or predict the best process parameters for a wide range of industrial materials.

References

I. Gibson, “Rapid prototyping: A review,” in Virtual Modelling and Rapid Manufacturing: Advanced Research in Virtual and Rapid Prototyping, Leiria, Portugal, 2005.

S. Pratheesh Kumar, S. Elangovan, R. Mohanraj, and J. R. Ramakrishna, “Review on the evolution and technology of State-of-the-Art metal additive manufacturing processes,” Materials Today, Mar. 2021.

I. Gibson, B. Stucker, and D. W. Rosen, Additive Manufacturing Technologies. New York, NY: Springer, 2009.

X. Yan and P. Gu, “A review of rapid prototyping technologies and systems,” Computer-Aided Design, vol. 28, no. 4, pp. 307–318, Apr. 1996.

R. M. Mahamood, Laser metal deposition process of metals, alloys, and composite materials, 1st ed. Cham, Switzerland: Springer International Publishing, 2017.

B. de La Batut, O. Fergani, V. Brotan, M. Bambach, and M. El Mansouri, “Analytical and numerical temperature prediction in direct metal deposition of Ti6Al4V,” Journal of Manufacturing and Materials Processing, vol. 1, no. 1, p. 3, Jul. 2017.

R. M. Mahamood and E. T. Akinlabi, “Experimental analysis of functionally graded materials using laser metal deposition process (case study),” in Functionally Graded Materials, Cham: Springer International Publishing, 2017, pp. 69–92.

A. J. Pinkerton, “Laser direct metal deposition: theory and applications in manufacturing and maintenance,” in Advances in Laser Materials Processing, Elsevier, 2010, pp. 461–491.

S. P. Kumar, S. Elangovan, R. Mohanraj, and B. Srihari, “Critical review of off-axial nozzle and coaxial nozzle for powder metal deposition,” Materials Today, Mar. 2021.

D. D. Gu, W. Meiners, K. Wissenbach, and R. Poprawe, “Laser additive manufacturing of metallic components: materials, processes and mechanisms,” International Materials Reviews, vol. 57, no. 3, pp. 133–164, May 2012.

A. Singh, S. Kapil, and M. Das, “A comprehensive review of the methods and mechanisms for powder feedstock handling in directed energy deposition,” Additive Manufacturing, vol. 35, no. 101388, p. 101388, Oct. 2020.

G. Piscopo, E. Atzeni, and A. Salmi, “A hybrid modeling of the physics-driven evolution of material addition and track generation in laser powder directed Energy Deposition,” Materials (Basel), vol. 12, no. 17, p. 2819, Sep. 2019.

W. U. H. Syed, A. J. Pinkerton, and L. Li, “Simultaneous wire- and powder-feed direct metal deposition: An investigation of the process characteristics and comparison with single-feed methods,” Journal of Laser Applications, vol. 18, no. 1, pp. 65–72, Feb. 2006.

M. Akbari and R. Kovacevic, “An investigation on mechanical and microstructural properties of 316LSi parts fabricated by a robotized laser/wire direct metal deposition system,” Additive Manufacturing, vol. 23, pp. 487–497, Oct. 2018.

R. M. Mahamood, E. T. Akinlabi, and M. G. Owolabi, “Effect of laser power and powder flow rate on dilution rate and surface finish produced during laser metal deposition of Titanium alloy,” presented at the 2017 8th International Conference on Mechanical and Intelligent Manufacturing Technologies (ICMIMT), Cape Town, South Africa, Feb. 2017.

S. Dadbakhsh, L. Hao, and C. Y. Kong, “Surface finish improvement of LMD samples using laser polishing,” Virtual and Physical Prototyping, vol. 5, no. 4, pp. 215–221, Dec. 2010.

S. P. Kumar, R. N. Anthuvan, K. Anand, S. S. Raj, P. M. S. Dhaman, and M. S. Kumar, “Technology overview of metal additive manufacturing processes,” Proceedings of the International Conference on Recent Advances in Manufacturing Engineering Research 2021: ICRAMER 2021, Chennai, India, 2022.

G. Zhu, D. Li, A. Zhang, G. Pi, and Y. Tang, “The influence of laser and powder defocusing characteristics on the surface quality in laser direct metal deposition,” Optics & Laser Technology, vol. 44, no. 2, pp. 349–356, Mar. 2012.

J. Zhang, S. Shi, G. Fu, J. Shi, G. Zhu, and D. Cheng, “Analysis on surface finish of thin-wall parts by laser metal deposition with annular beam,” Optics & Laser Technology, vol. 119, no. 105605, p. 105605, Nov. 2019.

H. S. Sun, S. H. Shi, G. Y. Fu, J. Zhang, C. Wang, and H. Y. Li, “Effect of defocus distance on layer quality in insider-laser coaxial powder feeding laser cladding,” Advanced Materials Research, vol. 287–290, pp. 2419–2422, Jul. 2011.

P. Gao, Z. Wang, and X. Zeng, “Effect of process parameters on morphology, sectional characteristics and crack sensitivity of Ti-40Al-9V-0.5Y alloy single tracks produced by selective laser melting,” International Journal of Lightweight Materials and Manufacture, vol. 2, no. 4, pp. 355–361, Dec. 2019.

L. Wang et al., “Laser direct metal deposition process of thin-walled parts using variable spot by inside-beam powder feeding,” Rapid Prototyping Journal, vol. 24, no. 1, pp. 18–27, Jan. 2018.

M. F. Erinosho, E. T. Akinlabi, and S. Pityana, “Effect of powder flow rate and gas flow rate on the evolving properties of deposited Ti6Al4V/Cu composites,” Advanced Materials Research, vol. 1016, pp. 177–182, Aug. 2014.

L. Li, Y. Huang, C. Zou, and W. Tao, “Numerical study on powder stream characteristics of coaxial laser metal deposition nozzle,” Crystals (Basel), vol. 11, no. 3, p. 282, Mar. 2021.

W. Li, X. Zhang, and F. Liou, “Modeling analysis of argon gas flow rate’s effect on pre-mixed powder separation in laser metal deposition process and experimental validation,” International Journal of Advanced Manufacturing Technology, vol. 96, no. 9–12, pp. 4321–4331, Jun. 2018.

M. P. Jahan, M. Rahman, and Y. S. Wong, “Micro-electrical discharge machining (micro-EDM),” in Comprehensive Materials Processing, Elsevier, 2014, pp. 333–371.

X. Wang, D. Deng, H. Yi, H. Xu, S. Yang, and H. Zhang, “Influences of pulse laser parameters on properties of AISI316L stainless steel thin-walled part by laser material deposition,” Optics & Laser Technology, vol. 92, pp. 5–14, Jul. 2017.

A. J. Pinkerton and L. Li, “An investigation of the effect of pulse frequency in laser multiple-layer cladding of stainless steel,” Applied Surface Science, vol. 208–209, pp. 405–410, Mar. 2003.

S. Pratheesh Kumar, S. Elangovan, R. Mohanraj, and V. Sathya Narayanan, “Significance of continuous wave and pulsed wave laser in direct metal deposition,” Materials Today, Mar. 2021.

E. Govekar, A. Jeromen, A. Kuznetsov, M. Kotar, and M. Kondo, “Annular laser beam based direct metal deposition,” Procedia CIRP, vol. 74, pp. 222–227, 2018.

D. Cheng et al., “Microstructure and mechanical properties of additive manufactured Ti-6Al-4V components by annular laser metal deposition in a semi-open environment,” Optics & Laser Technology, vol. 135, no. 106640, p. 106640, Mar. 2021.

K. Kumar, N. Kumari, and J. P. Davim, Eds., Non-conventional machining in modern manufacturing systems. IGI Global, 2019.

S. A. Lawal and M. B. Ndaliman, “Surface roughness characteristics in finish electro-discharge machining process,” in Encyclopedia of Smart Materials, Elsevier, 2017, pp. 477–487.

M. F. Erinosho, E. T. Akinlabi, and O. T. Johnson, “Effect of scanning speed on the surface roughness of laser metal deposited copper on titanium alloy,” Materials Research, vol. 22, no. 5, 2019.

S. Pratheesh Kumar, S. Elangovan, R. Mohanraj, and J. R. Ramakrishna, “A review on properties of Inconel 625 and Inconel 718 fabricated using direct energy deposition,” Materials Today, Mar. 2021.

M. Rombouts, G. Maes, W. Hendrix, E. Delarbre, and F. Motmans, “Surface finish after laser metal deposition,” Physics Procedia, vol. 41, pp. 810–814, 2013.

M. Gharbi et al., “Influence of various process conditions on surface finishes induced by the direct metal deposition laser technique on a Ti–6Al–4V alloy,” Journal of Materials Processing Technology, vol. 213, no. 5, pp. 791–800, May 2013.

M. Alimardani, V. Fallah, M. Iravani-Tabrizipour, and A. Khajepour, “Surface finish in laser solid freeform fabrication of an AISI 303L stainless steel thin wall,” Journal of Materials Processing Technology, vol. 212, no. 1, pp. 113–119, Jan. 2012.

V. G. Gusev and A. A. Fomin, “Multidimensional model of surface waviness treated by shaping cutter,” Procedia Engineering, vol. 206, pp. 286–292, 2017.

M. H. Shojaeefard, A. Khalkhali, and S. Shahbaz, “Analysis and optimization of the surface waviness in the single-point incremental sheet metal forming,” Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering, vol. 233, no. 4, pp. 919–925, Aug. 2019.

W. Grzesik, “Surface Integrity,” in Advanced Machining Processes of Metallic Materials, Elsevier, 2017, pp. 533–561.

H. Shen, C. Liao, J. Zhou, and K. Zhao, “Two-step laser based surface treatments of laser metal deposition manufactured Ti6Al4V components,” Journal of Manufacturing Processes, vol. 64, pp. 239–252, Apr. 2021.

M. Soodi, M. Brandt, and S. H. Masood, “A study of microstructure and surface hardness of parts fabricated by laser Direct Metal Deposition process,” Advanced Materials Research, vol. 129–131, pp. 648–651, Aug. 2010.

C. D. Naiju and P. M. Anil, “Influence of operating parameters on the reciprocating sliding wear of direct metal deposition (DMD) components using Taguchi method,” Procedia Engineering, vol. 174, pp. 1016–1027, 2017.

Q. Wang et al., “Functionally graded stainless steel fabricated by direct laser deposition: Anisotropy of mechanical properties and hardness,” Acta Metallurgica Sinica (English Letters), vol. 31, no. 1, pp. 19–26, Jan. 2018.

T. Bhardwaj, M. Shukla, N. K. Prasad, C. P. Paul, and K. S. Bindra, “Direct laser deposition-additive manufacturing of ti–15Mo alloy: Effect of build orientation induced surface topography on corrosion and bioactivity,” Metals and Materials International, vol. 26, no. 7, pp. 1015–1029, Jul. 2020.

L. Cao et al., “Study of surface topography detection and analysis methods of direct laser deposition 24CrNiMo alloy steel,” Optics & Laser Technology, vol. 135, no. 106661, p. 106661, Mar. 2021.

Y. Wu, B. Cui, and Y. Xiao, “Crack detection during laser metal deposition by infrared monochrome pyrometer,” Materials (Basel), vol. 13, no. 24, p. 5643, Dec. 2020.

W. Wang, A. J. Pinkerton, L. M. Wee, and L. Li, “Component repair using laser direct metal deposition,” in Proceedings of the 35th International MATADOR Conference, London: Springer London, 2007, pp. 345–350.

J. Yu, M. Rombouts, and G. Maes, “Cracking behavior and mechanical properties of austenitic stainless steel parts produced by laser metal deposition,” Materials & Design, vol. 45, pp. 228–235, Mar. 2013.

A. Sadhu et al., “A study on the influence of substrate pre-heating on mitigation of cracks in direct metal laser deposition of NiCrSiBC-60%WC ceramic coating on Inconel 718,” Surface and Coatings Technology, vol. 389, no. 125646, p. 125646, May 2020.

M. Brennan, J. S. Keist, and T. A. Palmer, “Defects in metal additive manufacturing processes,” in Additive Manufacturing Processes, ASM International, 2020, pp. 277–286.

A. Singh, A. Ramakrishnan, D. Baker, A. Biswas, and G. P. Dinda, “Laser metal deposition of nickel coated Al 7050 alloy,” Journal of Alloys and Compounds, vol. 719, pp. 151–158, Sep. 2017.

S. Nam, H. Cho, C. Kim, and Y.-M. Kim, “Effect of process parameters on deposition properties of functionally graded STS 316/Fe manufactured by laser direct metal deposition,” Metals (Basel), vol. 8, no. 8, p. 607, Aug. 2018.

G. K. Lewis and E. Schlienger, “Practical considerations and capabilities for laser assisted direct metal deposition,” Materials & Design, vol. 21, no. 4, pp. 417–423, Aug. 2000.

G. K. L. Ng, A. E. W. Jarfors, G. Bi, and H. Y. Zheng, “Porosity formation and gas bubble retention in laser metal deposition,” Applied Physics A - Materials Science & Processing, vol. 97, no. 3, pp. 641–649, Nov. 2009.

G. K. L. Ng, G. Bi, K. M. Teh, and H. Zheng, “An investigation on porosity in laser metal deposition,” presented at the ICALEO® 2008: 27th International Congress on Laser Materials Processing, Laser Microprocessing and Nanomanufacturing, Temecula, California, USA, 2008.

T. Jeon, T. Hwang, H. Yun, C. VanTyne, and Y. Moon, “Control of porosity in parts produced by a direct laser melting process,” Applied Sciences (Basel), vol. 8, no. 12, p. 2573, Dec. 2018.

A. Townsend, N. Senin, L. Blunt, R. K. Leach, and J. S. Taylor, “Surface texture metrology for metal additive manufacturing: a review,” Precision Engineering, vol. 46, pp. 34–47, Oct. 2016.

H. Pan, T. Sparks, Y. D. Thakar, and F. Liou, “The investigation of gravity-driven metal powder flow in coaxial nozzle for laser-aided direct metal deposition process,” Journal of Manufacturing Science & Engineering, vol. 128, no. 2, pp. 541–553, May 2006.

N. Sridharan, A. Chaudhary, P. Nandwana, and S. S. Babu, “Texture evolution during laser direct metal deposition of ti-6Al-4V,” The Journal of The Minerals, Metals & Materials Society (1989), vol. 68, no. 3, pp. 772–777, Mar. 2016.

J. Lu, L. Chang, J. Wang, L. Sang, S. Wu, and Y. Zhang, “In-situ investigation of the anisotropic mechanical properties of laser direct metal deposition Ti6Al4V alloy,” Materials Science & Engineering A: Structural Materials, vol. 712, pp. 199–205, Jan. 2018.

G. P. Dinda, A. K. Dasgupta, and J. Mazumder, “Laser aided direct metal deposition of Inconel 625 superalloy: Microstructural evolution and thermal stability,” Materials Science & Engineering A: Structural Materials, vol. 509, no. 1–2, pp. 98–104, May 2009.

M. N. Ahsan and A. J. Pinkerton, “An analytical–numerical model of laser direct metal deposition track and microstructure formation,” Modelling and Simulation in Materials Science and Engineering, vol. 19, no. 5, p. 055003, Jul. 2011.

Q.-L. Zhang, J.-H. Yao, and J. Mazumder, “Laser direct metal deposition technology and microstructure and composition segregation of inconel 718 superalloy,” Journal of Iron and Steel Research International, vol. 18, no. 4, pp. 73–78, Apr. 2011.

S. Bhattacharya, G. P. Dinda, A. K. Dasgupta, and J. Mazumder, “Microstructural evolution of AISI 4340 steel during Direct Metal Deposition process,” Materials Science & Engineering A: Structural Materials, vol. 528, no. 6, pp. 2309–2318, Mar. 2011.

R. M. Mahamood and E. T. Akinlabi, “Effect of powder flow rate on surface finish in laser additive manufacturing process,” IOP Conference Series: Materials Science and Engineering, vol. 391, p. 012005, Jul. 2018.

P. Peyre et al., “Surface finish issues after Direct Metal Deposition,” Materials Science Forum, vol. 706–709, pp. 228–233, Jan. 2012.

W. U. H. Syed and L. Li, “Effects of wire feeding direction and location in multiple layer diode laser direct metal deposition,” Applied Surface Science, vol. 248, no. 1–4, pp. 518–524, Jul. 2005.

W. U. H. Syed, A. J. Pinkerton, and L. Li, “Combining wire and coaxial powder feeding in laser direct metal deposition for rapid prototyping,” Applied Surface Science, vol. 252, no. 13, pp. 4803–4808, Apr. 2006.

T. Amine, J. W. Newkirk, and F. Liou, “An investigation of the effect of direct metal deposition parameters on the characteristics of the deposited layers,” Case Studies in Thermal Engineering, vol. 3, pp. 21–34, Jul. 2014.

M. K. Imran, S. H. Masood, M. Brandt, S. Bhattacharya, and J. Mazumder, “Direct metal deposition (DMD) of H13 tool steel on copper alloy substrate: Evaluation of mechanical properties,” Materials Science & Engineering A: Structural Materials, vol. 528, no. 9, pp. 3342–3349, Apr. 2011.

A. I. Gorunov and A. K. Gilmutdinov, “Study of the effect of heat treatment on the structure and properties of the specimens obtained by the method of direct metal deposition,” International Journal of Advanced Manufacturing Technology, vol. 86, no. 9–12, pp. 2567–2574, Oct. 2016.

B. Chen, Y. Yao, X. Song, C. Tan, L. Cao, and J. Feng, “Microstructure and mechanical properties of additive manufacturing AlSi10Mg alloy using direct metal deposition,” Ferroelectrics, vol. 523, no. 1, pp. 153–166, Jan. 2018.

M. Froend, S. Riekehr, N. Kashaev, B. Klusemann, and J. Enz, “Process development for wire-based laser metal deposition of 5087 aluminium alloy by using fibre laser,” Journal of Manufacturing Processes, vol. 34, pp. 721–732, Aug. 2018.

J.-D. Kim and Y. Peng, “Plunging method for Nd:YAG laser cladding with wire feeding,” Optics and Lasers in Engineering, vol. 33, no. 4, pp. 299–309, Apr. 2000.

J. Zhang, Y. Zhang, W. Li, S. Karnati, F. Liou, and J. W. Newkirk, “Microstructure and properties of functionally graded materials Ti6Al4V/TiC fabricated by direct laser deposition,” Rapid Prototyping Journal, vol. 24, no. 4, pp. 677–687, May 2018.

S. Bhattacharya, G. P. Dinda, A. K. Dasgupta, H. Natu, B. Dutta, and J. Mazumder, “Microstructural evolution and mechanical, and corrosion property evaluation of Cu–30Ni alloy formed by Direct Metal Deposition process,” Journal of Alloys and Compounds, vol. 509, no. 22, pp. 6364–6373, Jun. 2011.

B. Zheng, Y. Zhou, J. E. Smugeresky, and E. J. Lavernia, “Processing and behavior of Fe-based metallic glass components via laser-engineered net shaping,” Metallurgical and Materials Transactions A, vol. 40, no. 5, pp. 1235–1245, May 2009.

G. D. Janaki Ram, C. K. Esplin, and B. E. Stucker, “Microstructure and wear properties of LENS® deposited medical grade CoCrMo,” Journal of Materials Science: Materials in Medicine, vol. 19, no. 5, pp. 2105–2111, May 2008.

B. Li, B. Wang, G. Zhu, L. Zhang, and B. Lu, “Low-roughness-surface additive manufacturing of metal-wire feeding with small power,” Materials (Basel), vol. 14, no. 15, p. 4265, Jul. 2021.

M. O. Shaikh et al., “Additive manufacturing using fine wire-based laser metal deposition,” Rapid Prototyping Journal, vol. 26, no. 3, pp. 473–483, Nov. 2019.

A. J. Pinkerton, W. Wang, and L. Li, “Component repair using laser direct metal deposition,” Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, vol. 222, no. 7, pp. 827–836, Jul. 2008.

M. Jackson, A. Deshpande, A. Kim, and F. Pfefferkorn, “A study of particle size metrics using non-spherical feedstock for metal additive manufacturing,” Procedia Manufacturing, vol. 53, pp. 519–524, 2021.

R. M. Mahamood and E. T. Akinlabi, “Laser metal deposition of functionally graded Ti6Al4V/TiC,” Materials & Design, vol. 84, pp. 402–410, Nov. 2015.