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Title: Process window development of DED-LB/M process with coaxial wire for stainless steel AISI 316L

Authors: Panagiotis Stavropoulos; Harry Bikas; Konstantinos Tzimanis; Nikos Porevopoulos; Adriano Nicola Pilagatti; Eleonora Atzeni; Luca Iuliano; Alessandro Salmi

Addresses: Laboratory for Manufacturing Systems and Automation, Department of Mechanical Engineering and Aeronautics, University of Patras, Rion, 26504 Patras, Greece ' Laboratory for Manufacturing Systems and Automation, Department of Mechanical Engineering and Aeronautics, University of Patras, Rion, 26504 Patras, Greece ' Laboratory for Manufacturing Systems and Automation, Department of Mechanical Engineering and Aeronautics, University of Patras, Rion, 26504 Patras, Greece ' Laboratory for Manufacturing Systems and Automation, Department of Mechanical Engineering and Aeronautics, University of Patras, Rion, 26504 Patras, Greece ' Department of Management and Production Engineering, Politecnico di Torino, Corso Duca degli Abruzzi 24, 10129 Torino, Italy ' Department of Management and Production Engineering, Politecnico di Torino, Corso Duca degli Abruzzi 24, 10129 Torino, Italy ' Department of Management and Production Engineering, Politecnico di Torino, Corso Duca degli Abruzzi 24, 10129 Torino, Italy ' Department of Management and Production Engineering, Politecnico di Torino, Corso Duca degli Abruzzi 24, 10129 Torino, Italy

Abstract: This work is focused on the development of a process window for the laser-based directed energy deposition additive manufacturing (AM) process with coaxial wire as feedstock (DED-LB/M) as well as on the investigation of the significance of process parameters on the bead dimensions. This study employs a dual-pronged experimental approach: a one-factor-at-a-time (OFAT) evaluation for qualitative analysis of track dimensions and delineation of the process window, coupled with a full factorial design to derive response surfaces for AISI 316L stainless steel. The aim of this work is to identify the appropriate process parameters by examining the width, height and depth dimensions of the bead and the generation of process related knowledge so as to be used in further experimental work and for process control.

Keywords: directed energy deposition; DED; additive manufacturing; laser-based process; coaxial wire; bead dimensions; design of experiment; AISI 316L; process knowledge; process control.

DOI: 10.1504/IJEDPO.2024.138131

International Journal of Experimental Design and Process Optimisation, 2024 Vol.7 No.3, pp.1 - 26

Received: 28 Sep 2023
Accepted: 01 Jan 2024
Published online: 29 Apr 2024 *