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Energy Analysis For Process Parameter Prediction Of Direct Energy Deposition Metal Additive Manufacturing, Daniel John Pulscher

Graduate Research Theses & Dissertations

Metal Additive Manufacturing with the Direct Energy Deposition (DED) process allows for rapid prototyping and low-volume custom manufacturing of complex geometries at a lower cost than traditional manufacturing methods. Direct energy deposition is a complex process having many inter-related process parameters that effect the overall quality and mechanical properties of the build. When new powder feedstocks are used, calibrating these process parameters is typically done empirically in trials that can contain more than a hundred different combinations of parameters. This time-consuming process can be reduced by performing an analytical analysis on how the energy from the laser transfers into the …