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Distortion and Dilution Behavior for Laser Metal Deposition onto Thin Sheet Metals

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Abstract

The combination of additive manufacturing and incremental sheet forming offers great flexibility in the manufacture of function-integrated parts. In this study, both processes were carried out by the same CNC machine. This offers the possibility to manufacture large-scale lightweight parts with smaller additive parts on it in one machine and clamping device. Additionally, the process combination can lead to a reduced energy and material consumption for small batch sizes. DC01 sheets are used as a substrate with two different initial conditions. The first condition is as delivered steel sheet and the second is an incrementally formed with a thickness of 0.5 mm. The additive manufacturing was conducted by laser metal deposition (LMD). The powder material is a stainless steel 316 L. A segmentation of the cladding surface was applied and the path strategy of the laser movement was varied simultaneously to analyse the warpage of the thin substrate. It is shown that there is a dependency between the build-up strategies and the melt pool temperature, the thermal distortion, the dilution and the size of the cladding area. A segmentation of the working surface causes a lower melt pool temperature and thermal distortion. The lower melt pool temperature also generates a reduced dilution zone.

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Abbreviations

A Cl :

Cladding area

A Su :

Surface of substrate

∆T :

Temperature gradient

t 0 :

Initial sheet thickness

t 1 :

Sheet thickness after incremental sheet forming

Ψ :

Wall angel

w :

Out-of-plane distortion

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Acknowledgements

This work was supported by the Deutsche Forschungsgemeinschaft (DFG, German Research Foundation) in the frame of the project TE 508/68-1.

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Authors and Affiliations

  1. Institute of Forming Technology and Lightweight Components, TU Dortmund, 44227, Dortmund, Germany

    Lennart M. Tebaay, Marlon Hahn & A. Erman Tekkaya

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  1. Lennart M. Tebaay
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  2. Marlon Hahn
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  3. A. Erman Tekkaya
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Correspondence to Lennart M. Tebaay.

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Tebaay, L.M., Hahn, M. & Tekkaya, A.E. Distortion and Dilution Behavior for Laser Metal Deposition onto Thin Sheet Metals. Int. J. of Precis. Eng. and Manuf.-Green Tech. 7, 625–634 (2020). https://doi.org/10.1007/s40684-020-00203-9

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