Direct laser metal deposition additive manufacturing of Inconel 718 superalloy: statistical modelling and optimization by design of experiments

Mahmoud Moradi*, Arman Hasani, Zeynab Pourmand, Jonathan Lawrence

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review

27 Citations (Scopus)

Abstract

Direct laser metal deposition (DLMD) technique is used for additive manufacturing (AM) of Inconel 718 Ni-based superalloy using full factorial design. A 1 kW fiber laser is applied with a coupled coaxial nozzle head. Laser scanning speed (2.5–5.0 mm/s), powder feed rate (17.94–28.52 g/min), and scanning strategies (Unidirectional, Bidirectional) were considered as the input process variables while geometrical dimensions (height, width average), standard deviation of microhardness, and the stability of additively manufactured walls were determined as process responses. The influence of process parameters on the responses variations were studied by analysis of variance (ANOVA). Results indicated that low scanning speed and high powder feed rate caused to increase in height and average width of AM samples. Due to microstructural phases, the microhardness changes have an unstable trend. Results show that a stable wall was obtained in low scanning speed and unidirectional scanning pattern. In order to achieve a desired condition for the DLMD additive manufacturing process, optimization was conducted based on the applied statistical analyses. The scanning speed of 2.5 mm/s, the powder feed rate of 28.52 g/min, and unidirectional scanning pattern were identified as the optimum conditions.
Original languageEnglish
Article number107380
JournalOptics & Laser Technology
Volume144
Early online date14 Jul 2021
DOIs
Publication statusPublished - 31 Dec 2021
Externally publishedYes

Keywords

  • additive manufacturing
  • direct laser metal deposition
  • Inconel 718
  • design of experiments
  • optimization

Fingerprint

Dive into the research topics of 'Direct laser metal deposition additive manufacturing of Inconel 718 superalloy: statistical modelling and optimization by design of experiments'. Together they form a unique fingerprint.

Cite this