Abstract
Directed Energy Deposition (DED) is a promising technology for producing metal matrix composites (MMXCs), but precise control over deposited layer dimensions, particularly in multi-material systems, remains difficult to achieve due to the complex interdependence of operating parameters such as laser parameters, feedstock flow rate, and beam energy attenuation. To address these problems, this work proposes an analytical model that predicts the width, height, and depth of the deposited layers using mixed feedstock compositions in-situ, with a focus on Inconel-718 and TiC MMXCs. The model takes into account variables such as laser power, feedstock density, and mixing ratios to improve layer accuracy and minimize the number of experimental attempts. The main findings reveal that TiC additions increase thermal stability and potential wear resistance properties. The model predictions closely match the experimental data, with layer dimension deviations of less than 5.0% between the simulated and observed values, indicating efficient process control for DED multi-material production.
Recommended Citation
M. A. Mahmood et al., "DED Printing Process Modeling using Metal Matrix Composites: In-Situ Feedstock Mixing with Variable Compositions and Empirical Validation," International Journal of Advanced Manufacturing Technology, vol. 141, no. 5 thru 6, pp. 3347 - 3360, Springer, Nov 2025.
The definitive version is available at https://doi.org/10.1007/s00170-025-16828-6
Department(s)
Mechanical and Aerospace Engineering
Keywords and Phrases
Analytical modeling; DED; In-situ feedstock mixing; Layer dimension prediction; Metal matrix composites; Multi-material fabrication
International Standard Serial Number (ISSN)
1433-3015; 0268-3768
Document Type
Article - Journal
Document Version
Citation
File Type
text
Language(s)
English
Rights
© 2025 Springer, All rights reserved.
Publication Date
01 Nov 2025
Comments
Colegiul Consultativ pentru Cercetare-Dezvoltare şi Inovare, Grant PN-IV-P7-7.1-PTE-2024-0336