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Lasers in Manufacturing and Materials Processing

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24-11-2022

Laser-Based Directed Energy Deposition (L-DED) Processing of Water Atomized 42CrMo4 Powder

Authors: G. A. W. Sweet, I. W. Donaldson, C. T. Schade, D. P. Bishop

Published in: Lasers in Manufacturing and Materials Processing | Issue 1/2023

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Abstract

This study investigates the viability of utilizing a low-cost steel feedstock powder in the context of laser-based directed energy deposition (DED) processing. Here, water atomized 42CrMo4 (comparable to 4140) ferrous powder was deposited on a AISI 4140 substrate using an Optomec MTS 500-AM controlled atmosphere DED system. A statistical design of experiments (DOE) approach was used to parametrically model the effects of laser power, laser scan speed, hatch spacing, layer thickness and powder feed rate on the density of the deposited product. The direct impact of these variables was assessed as well as their respective interactions. The resultant model was found to be highly significant and maintained a capacity to predict future results. It was then leveraged to identify a set of deposition parameters that produced high quality deposits with near full theoretical density. The effects of pre and post-build heat treatments on the microstructure, microhardness, and residual stress of L-DED deposits were assessed as well.

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Title: Laser-Based Directed Energy Deposition (L-DED) Processing of Water Atomized 42CrMo4 Powder
Authors: G. A. W. Sweet
I. W. Donaldson
C. T. Schade
D. P. Bishop
Publication date: 24-11-2022
Publisher: Springer US
Published in: Lasers in Manufacturing and Materials Processing / Issue 1/2023
Print ISSN: 2196-7229
Electronic ISSN: 2196-7237
DOI: https://doi.org/10.1007/s40516-022-00196-0

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