1. Experimental study of balling defect generation and audible sound analysis in directed energy deposition metal additive manufacturing.
- Author
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Wu, Cong-Yue, Lu, Ming-Chyuan, Yang, Wei-Chun, and Chi, Nai-Chia
- Subjects
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LIQUID metals , *MICROELECTROMECHANICAL systems , *SURFACE energy , *THERMOGRAPHY , *LOUDNESS - Abstract
Monitoring the defects generated during metal additive manufacturing is crucial for maintaining high manufacturing quality and extending the applications of this technology to various industries. In this study, balling defect generation was studied through the experimental investigation of directed energy deposition (DED) of Inconel 718 alloy on stainless steel. The relationships of deposition size and balling defects with audible sound were analyzed. Microelectromechanical systems microphones were installed around the Inconel 718 deposition spot to collect audible sound signals. Moreover, a high-speed optical camera and a thermal camera were used to collect real-time optical and thermal images, respectively, during deposition. The results of this study indicate that the surface energy of the liquid metal in DED has a crucial effect on the geometry of the melt pool. The accumulation of melt material because of the surface energy causes a shift in the deposition position away from the front edge of previously deposited material and is the primary factor causing balling defects. Sound signal analysis confirmed strong correlations between the features of audible sound and the melt volume in single-point deposition experiments. The relationships between the features of audible sound and balling defects were also determined. The time and frequency features of collected audible sound signals can be used to identify the generation of balling defects in the DED of Inconel 718. [ABSTRACT FROM AUTHOR]
- Published
- 2024
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