A comparative study of wire feeding and powder feeding in direct diode laser deposition for rapid prototyping

Waheed Ul Haq Syed; Andrew J. Pinkerton; Lin Li

doi:10.1016/j.apsusc.2005.01.138

A comparative study of wire feeding and powder feeding in direct diode laser deposition for rapid prototyping

Waheed Ul Haq Syed, Andrew J. Pinkerton, Lin Li

Mechanical and Aerospace Engineering

Research output: Contribution to journal › Article › peer-review

Abstract

Metal powder feeding has been used widely in various rapid prototyping and tooling processes such as direct laser deposition (DLD) and layered engineered net shaping (LENS) to achieve near net shape accuracy. Although powder recycling has been practiced, the material usage efficiency has been very low (normally below 30%). This study compares the process characteristics, advantages and disadvantages of wire- and powder-feed DLD. A 1.5 kW diode laser is used to build multiple layer parts, which are compared and analysed in terms of surface finish, microstructure and deposition efficiency. Scanning electron microscopy (SEM), X-ray diffraction and optical microscopy are used for the material characterisation. The microstructure of samples from both the methods is similar, with some porosity found in powder-feed components, but the surface finish and material usage efficiency is better for wire-feed samples. The deposition angle is found to be critical in the case of wire feeding and the characteristics of different feed angles are explored. Possible reasons for the different characteristics of the two deposition techniques are discussed. © 2005 Elsevier B.V. All rights reserved.

Original language	English
Pages (from-to)	268-276
Number of pages	8
Journal	Applied Surface Science
Volume	247
Issue number	1-4
DOIs	https://doi.org/10.1016/j.apsusc.2005.01.138
Publication status	Published - 15 Jul 2005

Keywords

Laser deposition
Powder feeding
Rapid prototyping
Wire feeding

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

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10.1016/j.apsusc.2005.01.138

LPRC: Laser Processing Research Centre Impact
Allegre, O. (PI), Crosby, D. (PI), Domingos, M. (PI), Francis, J. (PI), Gillen, D. (PI), Guo, W. (PI), Li, L. (PI), Mativenga, P. (PI), Rogers, B. D. (PI), Whitehead, D. (PI), Wilson, D. (PI), Zhong, S. (PI), Mirhosseini, N. (Researcher), Ouyang, J. (Researcher), Huang, Y. (Researcher), Wei, C. (Researcher), Cheng, D. (PGR student), Suryo Pratomo, E. (PGR student), Zhang, Z. (PGR student), Li, Z. (PGR student), Mo, H. (PGR student), Zhu, M. (PGR student), Li, Q. (PGR student), Liu, W. (PGR student), Wang, L. (PGR student), Guo, H. (PGR student), Heinemann, R. (PI) & Liu, Z. (PI)
1/04/00 → …
Project: Research

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title = "A comparative study of wire feeding and powder feeding in direct diode laser deposition for rapid prototyping",

abstract = "Metal powder feeding has been used widely in various rapid prototyping and tooling processes such as direct laser deposition (DLD) and layered engineered net shaping (LENS) to achieve near net shape accuracy. Although powder recycling has been practiced, the material usage efficiency has been very low (normally below 30%). This study compares the process characteristics, advantages and disadvantages of wire- and powder-feed DLD. A 1.5 kW diode laser is used to build multiple layer parts, which are compared and analysed in terms of surface finish, microstructure and deposition efficiency. Scanning electron microscopy (SEM), X-ray diffraction and optical microscopy are used for the material characterisation. The microstructure of samples from both the methods is similar, with some porosity found in powder-feed components, but the surface finish and material usage efficiency is better for wire-feed samples. The deposition angle is found to be critical in the case of wire feeding and the characteristics of different feed angles are explored. Possible reasons for the different characteristics of the two deposition techniques are discussed. {\textcopyright} 2005 Elsevier B.V. All rights reserved.",

keywords = "Laser deposition, Powder feeding, Rapid prototyping, Wire feeding",

author = "Syed, {Waheed Ul Haq} and Pinkerton, {Andrew J.} and Lin Li",

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doi = "10.1016/j.apsusc.2005.01.138",

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AU - Syed, Waheed Ul Haq

AU - Pinkerton, Andrew J.

AU - Li, Lin

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Y1 - 2005/7/15

N2 - Metal powder feeding has been used widely in various rapid prototyping and tooling processes such as direct laser deposition (DLD) and layered engineered net shaping (LENS) to achieve near net shape accuracy. Although powder recycling has been practiced, the material usage efficiency has been very low (normally below 30%). This study compares the process characteristics, advantages and disadvantages of wire- and powder-feed DLD. A 1.5 kW diode laser is used to build multiple layer parts, which are compared and analysed in terms of surface finish, microstructure and deposition efficiency. Scanning electron microscopy (SEM), X-ray diffraction and optical microscopy are used for the material characterisation. The microstructure of samples from both the methods is similar, with some porosity found in powder-feed components, but the surface finish and material usage efficiency is better for wire-feed samples. The deposition angle is found to be critical in the case of wire feeding and the characteristics of different feed angles are explored. Possible reasons for the different characteristics of the two deposition techniques are discussed. © 2005 Elsevier B.V. All rights reserved.

AB - Metal powder feeding has been used widely in various rapid prototyping and tooling processes such as direct laser deposition (DLD) and layered engineered net shaping (LENS) to achieve near net shape accuracy. Although powder recycling has been practiced, the material usage efficiency has been very low (normally below 30%). This study compares the process characteristics, advantages and disadvantages of wire- and powder-feed DLD. A 1.5 kW diode laser is used to build multiple layer parts, which are compared and analysed in terms of surface finish, microstructure and deposition efficiency. Scanning electron microscopy (SEM), X-ray diffraction and optical microscopy are used for the material characterisation. The microstructure of samples from both the methods is similar, with some porosity found in powder-feed components, but the surface finish and material usage efficiency is better for wire-feed samples. The deposition angle is found to be critical in the case of wire feeding and the characteristics of different feed angles are explored. Possible reasons for the different characteristics of the two deposition techniques are discussed. © 2005 Elsevier B.V. All rights reserved.

KW - Laser deposition

KW - Powder feeding

KW - Rapid prototyping

KW - Wire feeding

U2 - 10.1016/j.apsusc.2005.01.138

DO - 10.1016/j.apsusc.2005.01.138

M3 - Article

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VL - 247

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EP - 276

JO - Applied Surface Science

JF - Applied Surface Science

IS - 1-4

ER -

A comparative study of wire feeding and powder feeding in direct diode laser deposition for rapid prototyping

Abstract

Keywords

UN SDGs

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LPRC: Laser Processing Research Centre Impact

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