Metal Additive Manufacturing Conference - MAMC 2023

Wire-based directed energy deposition (w-DED) is a sophisticated technology for producing structural components. Managing bead features and defining process parameters are critical parts of the w-DED process for producing a flawless final product with minimal material waste. Based on thermo-physical relations, a thermo-capillary-gravity bidirectional model has been devised in this study for rapid prediction of bead geometries or process parameters of w-DED. Bead geometries can be predicted using process parameters and material properties in the forward algorithm. In the backward algorithm, inputs of bead geometries and material properties yield process parameters as outputs. The bi-directional model has been validated for the deposition of 316L with the laser DED, ER90S-G steel with plasma transferred arc (PTA), and cold wire gas metal arc (CW-GMA) processes.