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<p>Laser-powder directed energy deposition (LP-DED) is a promising technique in aerospace for repair, addition of functionalities, and graded material manufacturing. Advancing process maturity requires a deeper understanding of the complex interdependencies between process parameters, physical phenomena, and final part quality. To investigate the relationship between thermal phenomena, power (P), speed (V), and defect formation, 316&#xa0;L single-bead walls were produced and monitored using an IR camera. Defects such as deviations in wall height, staggered stacking, and layer unevenness were identified. This study revealed that stacking defects are closely linked to bead shape and melt pool stability, both influenced by P and V. These defects lead to a loss of working distance, which in turn promotes uneven layers. However, a compensation effect within the process allowed walls with uneven layers to be correctly built under certain conditions. When stacking defects became too severe, chaotic regimes emerged, compromising the deposition quality. Melt pool height and temperature data extracted from IR imaging highlighted the presence of these defects and provided insights into intermediate cases where compensation occurs, but other defects remain too pronounced to ensure proper wall construction. Finally, the implemented instrumentation gives promising insight into the prediction and traceability of defects.</p>

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Defect detection in 316 L single-bead walls using the instrumentation of a LP-DED process

  • 期刊论文

  • 发表日期：

    2025年10月8日

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  • Lilou de Peindray d’Ambelle,
  • Kamel Moussaoui,
  • Catherine Mabru

摘要

Laser-powder directed energy deposition (LP-DED) is a promising technique in aerospace for repair, addition of functionalities, and graded material manufacturing. Advancing process maturity requires a deeper understanding of the complex interdependencies between process parameters, physical phenomena, and final part quality. To investigate the relationship between thermal phenomena, power (P), speed (V), and defect formation, 316 L single-bead walls were produced and monitored using an IR camera. Defects such as deviations in wall height, staggered stacking, and layer unevenness were identified. This study revealed that stacking defects are closely linked to bead shape and melt pool stability, both influenced by P and V. These defects lead to a loss of working distance, which in turn promotes uneven layers. However, a compensation effect within the process allowed walls with uneven layers to be correctly built under certain conditions. When stacking defects became too severe, chaotic regimes emerged, compromising the deposition quality. Melt pool height and temperature data extracted from IR imaging highlighted the presence of these defects and provided insights into intermediate cases where compensation occurs, but other defects remain too pronounced to ensure proper wall construction. Finally, the implemented instrumentation gives promising insight into the prediction and traceability of defects.