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<p>Uniform-section tubular structures are predominantly manufactured via metal superplastic forming, whereas the fabrication of variable-section tubular structures with torsion and bending characteristics remains challenging. This study proposes a adaptive multi-directional slicing (AMDS) method based on annular laser powder deposition (ALPD). By dynamically adjusting the coaxial nozzle orientation via a multi-axis robot, this method achieves non-parallel slicing and variable-height deposition. Adaptive matching between the coordinates of discrete deposition units and the variable-height deposition process achieved the supportless manufacturing of warped tube. A variable section tube with 45°torsion and 90°bending features was fabricated using a custom-built ALPD platform. The formed part was comprehensively characterized in terms of geometric accuracy, density, microstructure, and microhardness. Geometric analysis indicated a surface deviation range of -0.148 to + 0.349&#xa0;mm. Density analysis of samples extracted from both inner and outer curvature sides of the tube revealed densities exceeding 99% in all cases, with few pores and no cracks. Microstructural analysis and microhardness measurements indicated that increasing the scanning speed during fabrication resulted in grain refinement and a corresponding increase in the average hardness. This study validates the feasibility of ALPD for manufacturing dimensionally stable, defect-free complex warped tubular structures, thereby expanding its industrial application potential.</p>

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Additive manufacturing of variable section warped tubular structures via annular laser powder deposition

  • 期刊论文

  • 发表日期：

    2026年3月13日

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  • Rongwei Zhang,
  • Tuo Shi,
  • Geyan Fu,
  • Shihong Shi,
  • Le Wan

摘要

Uniform-section tubular structures are predominantly manufactured via metal superplastic forming, whereas the fabrication of variable-section tubular structures with torsion and bending characteristics remains challenging. This study proposes a adaptive multi-directional slicing (AMDS) method based on annular laser powder deposition (ALPD). By dynamically adjusting the coaxial nozzle orientation via a multi-axis robot, this method achieves non-parallel slicing and variable-height deposition. Adaptive matching between the coordinates of discrete deposition units and the variable-height deposition process achieved the supportless manufacturing of warped tube. A variable section tube with 45°torsion and 90°bending features was fabricated using a custom-built ALPD platform. The formed part was comprehensively characterized in terms of geometric accuracy, density, microstructure, and microhardness. Geometric analysis indicated a surface deviation range of -0.148 to + 0.349 mm. Density analysis of samples extracted from both inner and outer curvature sides of the tube revealed densities exceeding 99% in all cases, with few pores and no cracks. Microstructural analysis and microhardness measurements indicated that increasing the scanning speed during fabrication resulted in grain refinement and a corresponding increase in the average hardness. This study validates the feasibility of ALPD for manufacturing dimensionally stable, defect-free complex warped tubular structures, thereby expanding its industrial application potential.