| Abstract Scope |
With emerging applications in wire-arc directed-energy deposition (DED-Arc) additive manufacturing (AM), understanding how material-specific microstructure and defects impact macro-scale properties is critical. Most DED-Arc defects can be categorized into porosity-type defects, characterized by voids, and residual stress-type defects, characterized by stresses that remain even after exterior loading has been removed. Residual stresses result from repetitive heating/cooling cycles as well as melt pool shrinkage during solidification, and contribute to part failure through cracking, plastic deformation, and distortion. The objective of this investigation is to understand formation mechanisms of common defects that occur during DED-Arc, establish a process window, and correlate sensor responses to expected defects throughout the processing space. Understanding how process parameters, particularly arc power, travel speed, and wire-feed rate, are related to process emissions for sensor detection can help regulate the formation of defects to produce optimized DED-Arc parts. |