Interplay between powder catchment efficiency and layer height in self-stabilized laser metal deposition

TL;DR

This study investigates how the stability of layer height in laser metal deposition is linked to powder catchment efficiency, using real-time monitoring and an analytical model to optimize process parameters for consistent build quality.

Contribution

It introduces a monitoring system and analytical model to analyze the relationship between powder catchment efficiency and height stability in LMD processes.

Findings

Height stabilization correlates with reduced powder catchment efficiency.

Optimal standoff distance improves powder catchment efficiency and height consistency.

The melt pool position influences powder catchment and process stability.

Abstract

In laser metal deposition (LMD) the height of the deposited track can vary within and between layers, causing significant deviations during the process evolution. Previous works have shown that in certain conditions a self-stabilizing mechanism occurs, maintaining a regular height growth and a constant standoff distance between the part and the deposition nozzle. Here we analyze the link between the powder catchment efficiency and the deposition height stability. To this purpose, a monitoring system was developed to study the deposition in different process conditions, using inline measurements of the specimen weight in combination with the layer height information obtained with coaxial optical triangulation. An analytical model was used to estimate the deposition efficiency in real-time from the height monitoring and the process parameters, which was verified by the direct mass measurements. The results show that the track height stabilization is associated to a reduction of the powder catchment efficiency, which is governed by the melt pool relative position with respect to the powder cone and the laser beam. For a given set of parameters, the standoff distance can be estimated to achieve the highest powder catchment efficiency and a regular height through the build direction.