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<p>The laser direct metal deposition (LDMD) process, an additive manufacturing technique, creates components by fusing materials layer-by-layer, with part quality significantly influenced by process parameters. Optimizing these parameters is essential for improving material efficiency and part durability. This study addresses the need to enhance powder catchment efficiency (PCE) in LDMD, specifically for Stelcar 65 alloy, a material used in high-wear and high-temperature applications. Utilizing process variables such as scanning speed and laser power, this research employs mathematical–statistical RSM to identify ideal conditions for maximizing PCE. Experimental data were analyzed and optimized, resulting in a PCE model that closely matched empirical results with a 98.52% accuracy. The findings underscore that optimal parameter selection can substantially elevate component quality in LDMD processes. These insights are particularly beneficial for manufacturers in aerospace, tooling, and other high-precision industries, enabling the efficient application of Stelcar 65 in producing superior-quality components.</p>

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Powder catchment efficiency optimisation of Stelcar 65 fabricated by laser direct metal deposition

  • 期刊论文

  • 发表日期：

    2025年5月25日

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  • S. Pratheesh Kumar,
  • Rithika Jayabharathi Yuvarajan

摘要

The laser direct metal deposition (LDMD) process, an additive manufacturing technique, creates components by fusing materials layer-by-layer, with part quality significantly influenced by process parameters. Optimizing these parameters is essential for improving material efficiency and part durability. This study addresses the need to enhance powder catchment efficiency (PCE) in LDMD, specifically for Stelcar 65 alloy, a material used in high-wear and high-temperature applications. Utilizing process variables such as scanning speed and laser power, this research employs mathematical–statistical RSM to identify ideal conditions for maximizing PCE. Experimental data were analyzed and optimized, resulting in a PCE model that closely matched empirical results with a 98.52% accuracy. The findings underscore that optimal parameter selection can substantially elevate component quality in LDMD processes. These insights are particularly beneficial for manufacturers in aerospace, tooling, and other high-precision industries, enabling the efficient application of Stelcar 65 in producing superior-quality components.