Laser directed energy deposition of water-atomized iron powder: Process optimization and microstructure of single-tracks. (15th April 2019)

• Record Type: Journal Article
• Authors: Ansari, Mohammad; Mohamadizadeh, Alireza; Huang, Yuze; Paserin, Vladimir; Toyserkani, Ehsan
• Is Part Of: Optics & laser technology. Volume 112(2019)
• Page Start: 485
• Page End: 493
• Publication Date: 2019-04-15
• Subjects: Additive manufacturing -- Laser directed energy deposition -- Iron powder -- Microstructure -- Statistical analysis -- Optimization; Optics -- Periodicals; Lasers -- Periodicals; Electronic journals; 621.366
• DOI: 10.1016/j.optlastec.2018.11.054
• Languages: English
• ISSNs: 0030-3992

Abstract

Highlights: Laser directed energy deposition of water-atomized iron powder was performed. Response surface methodology was used for process optimization of single-tracks. Regression models were developed and tested by analysis of variance. The optimal processing window was identified using the desirability function. Microstructure and phase composition of the single-tracks were investigated. Abstract: Although iron, as a basic metal, has been used commonly in industry, the use of an advanced technique such as additive manufacturing (AM) may offer more opportunities. For example, AM of iron-based powders for functional prototypes would likely be beneficial in the automotive industry, since this industry has commonly used iron alloys for prototypes and functional parts produced by conventional technologies. This paper presents Laser Directed Energy Deposition through Powder Feeding (LDED-PF), a class of AM, of irregular-shape inexpensive water-atomized iron powder. A setup with a lateral powder-fed nozzle was deployed to deposit single-tracks using different processing parameters. The experimental design and optimization model were implemented based on the response surface methodology when the regression model was tested by the variance analysis. The desirability function was used to identify the optimal processing window to obtain the single-tracks with a minimized dilution and a maximized bead height and high powder efficiency. The results showed that the geometrical characteristics of the single-tracks have a high dependency on the key LDED-PF processing parameters. In addition, the microstructure and phase composition of the single-tracks were investigated by SEM and EDS, revealing that the deposits were generally composed of the ferrite phase.