Sidewall shape control using direct laser fabrication technology.

The sidewall collapse of laser forming parts severely affects the forming quality of these parts. In this study, a strategy for the shape control of sidewalls using direct laser fabrication technology was systematically investigated. To this end, a three-dimensional (3D) model of the collapse area was constructed using SolidWorks. In addition, a horizontal equally high stratification was achieved using the linear relationship between the cladding height and scanning speed. Further, the number of scanning tracks of each layer was designed using the linear relationship between the cladding width, laser power, and number of scanning tracks. Using the aforementioned processing method, the edge of the forming part was fitted into a specially shaped base surface to ensure the gradual accumulation of the forming part on the sidewall. The results reveal that a maximum relative dimensional error of the forming parts (19.5%) was achieved via the metallurgical bonding between the base surface and the forming part. In addition, the parts exhibited a dense and uniform microstructure without notable cracks, pores, and other defects and a microhardness of 273.4–313.6 HV. [ABSTRACT FROM AUTHOR]