Abstract
Wire-based laser metal deposition is an additive manufacturing process that can be used in the efficient manufacturing of complex structures. This paper utilizes a three-beam coaxial laser wire system to explore the effect of process parameters on the resultant deposition density. The reduction in or elimination of defects is important to the mechanical properties of the additively manufactured material and the widespread adoption of additive manufacturing processes. In this work, two-bead-wide walls were deposited under varying experimental conditions, including the traverse feed rate and workpiece illumination proportion. A method for calculating the bead pitch and layer height increment based on the geometry of the deposited material was developed. The deposited samples were micro-CT-scanned to characterize internal defects at a high resolution. The volume of the detected defects was measured and compared to the total sample volume to calculate a defect rate for each run of the experiment. The traverse feed rate and defocusing level were found to have a significant impact on the output defect rate. As these process parameters were increased, the defect rate decreased. Across the experimental levels, the defect volume percentage was reduced from 1.021% to 0.062%. This reduction in internal defect size enhances the material's mechanical performance and ensures its suitability for aerospace applications.
Recommended Citation
R. Mathenia et al., "Experimental Study of Process Parameter Effects on Internal Defects in Titanium Coaxial Wire-Based Laser Metal Deposition," Metals, vol. 15, no. 5, article no. 499, MDPI, May 2025.
The definitive version is available at https://doi.org/10.3390/met15050499
Department(s)
Mechanical and Aerospace Engineering
Publication Status
Open Access
Keywords and Phrases
defect analysis; defocusing; three-beam coaxial laser; wire deposition
International Standard Serial Number (ISSN)
2075-4701
Document Type
Article - Journal
Document Version
Final Version
File Type
text
Language(s)
English
Rights
© 2025 The Authors, All rights reserved.
Creative Commons Licensing
This work is licensed under a Creative Commons Attribution 4.0 License.
Publication Date
01 May 2025
Comments
Missouri University of Science and Technology, Grant None