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Abstract <p>The Laser-Directed Energy Deposition with powder (DED-LB/powder) process is a promising additive manufacturing technology, but challenges remain in stabilizing deposit conditions and enhancing material efficiency. This study introduces a layer-scale model for predicting Powder Catchment Efficiency (PCE) and wall mass, based on in-operando measurements of stand-off distance and melt pool area, combined with offline characterization of the powder stream distribution. For the first time, a fully experimental model is proposed, revealing a self-stabilization regime where layer height naturally matches the vertical increment between layers. Using 316&#xa0;L stainless steel and a coaxial RGB camera as a bichromatic pyrometer (using the <i>single-camera two-wavelength imaging pyrometry</i> (STWIP) method), we demonstrate that the model predicts the PCE with a relative error of maximum 15%. A comprehensive uncertainty analysis highlights the model sensitivity to initial nozzle-to-substrate distance, melt pool area, and powder focal plane position. This work provides a robust framework for real-time monitoring and optimization of the DED-LB/powder process.</p> Graphical abstract <p></p>

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Revisiting catchment efficiency and self-stabilization of the DED-LB/powder process by an in-operando monitoring results-based model

  • 期刊论文

  • 发表日期：

    2026年6月15日

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  • Maxime Rey,
  • Nicolas Tardif,
  • Joel Lachambre,
  • Mady Guillemot,
  • Frederic Vignat,
  • Thomas Elguedj

摘要

Abstract

The Laser-Directed Energy Deposition with powder (DED-LB/powder) process is a promising additive manufacturing technology, but challenges remain in stabilizing deposit conditions and enhancing material efficiency. This study introduces a layer-scale model for predicting Powder Catchment Efficiency (PCE) and wall mass, based on in-operando measurements of stand-off distance and melt pool area, combined with offline characterization of the powder stream distribution. For the first time, a fully experimental model is proposed, revealing a self-stabilization regime where layer height naturally matches the vertical increment between layers. Using 316 L stainless steel and a coaxial RGB camera as a bichromatic pyrometer (using the single-camera two-wavelength imaging pyrometry (STWIP) method), we demonstrate that the model predicts the PCE with a relative error of maximum 15%. A comprehensive uncertainty analysis highlights the model sensitivity to initial nozzle-to-substrate distance, melt pool area, and powder focal plane position. This work provides a robust framework for real-time monitoring and optimization of the DED-LB/powder process.

Graphical abstract