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<p>Although additive manufacturing (AM) has gained significant attention in academia, limited studies have thoroughly examined the design considerations and challenges in fabricating thin walls using laser powder-directed energy deposition (LP-DED). This study assesses the feasibility of producing Inconel 718 thin walls with thicknesses below 0.8 mm. It examines the influence of key LP-DED parameters, such as laser power, scanning speed, and mass flow rate, on geometrical dimensions (average height and width), surface texture (3D surface roughness, waviness, and straightness), microhardness, and microstructure. Additionally, analysis of variance (ANOVA) is used to evaluate the impact of process parameters on response variations. The findings show that a higher scanning speed reduces wall dimensions, while an increased powder feeding rate raises wall height with minimal effect on width. Additionally, greater laser power widens the wall but reduces its height and microhardness. The optimal process parameters are identified as a laser power of 300 W, a scanning speed of 2000 mm/min, and a mass flow rate of 4 g/min. Under these conditions, the fabricated thin wall achieved a minimum thickness of 0.70 mm. It also exhibited a minimum surface roughness (Sa) of 8.235 µm and a minimum waviness (Wa) of 14.02 µm, while demonstrating the highest recorded microhardness of 342.7 HV. A clear understanding of as-built surface texture in the LP-DED process is crucial for fluid flow applications, such as heat exchangers, as it can either enhance heat transfer efficiency or negatively impact pressure drop.</p>

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Analysis of process parameters in the fabrication of thin-wall Inconel 718 via laser-directed energy deposition

  • 期刊论文

  • 发表日期：

    2025年3月5日

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  • Seyedali Momeni,
  • Reginaldo Teixeira Coelho,
  • Danver Messias Bruno,
  • Renato Goulart Jasinevicius

摘要

Although additive manufacturing (AM) has gained significant attention in academia, limited studies have thoroughly examined the design considerations and challenges in fabricating thin walls using laser powder-directed energy deposition (LP-DED). This study assesses the feasibility of producing Inconel 718 thin walls with thicknesses below 0.8 mm. It examines the influence of key LP-DED parameters, such as laser power, scanning speed, and mass flow rate, on geometrical dimensions (average height and width), surface texture (3D surface roughness, waviness, and straightness), microhardness, and microstructure. Additionally, analysis of variance (ANOVA) is used to evaluate the impact of process parameters on response variations. The findings show that a higher scanning speed reduces wall dimensions, while an increased powder feeding rate raises wall height with minimal effect on width. Additionally, greater laser power widens the wall but reduces its height and microhardness. The optimal process parameters are identified as a laser power of 300 W, a scanning speed of 2000 mm/min, and a mass flow rate of 4 g/min. Under these conditions, the fabricated thin wall achieved a minimum thickness of 0.70 mm. It also exhibited a minimum surface roughness (Sa) of 8.235 µm and a minimum waviness (Wa) of 14.02 µm, while demonstrating the highest recorded microhardness of 342.7 HV. A clear understanding of as-built surface texture in the LP-DED process is crucial for fluid flow applications, such as heat exchangers, as it can either enhance heat transfer efficiency or negatively impact pressure drop.