Characterization Of Single Track Formation From Ti-6AL-4V Alloy At Different Process Parameters By Direct Energy Deposition

Optimization of process parameters (such as laser power, laser speed, focus, etc.) for metal powders in Direct Energy Deposition (DED) is usually performed through the experimental investigations. However, this sort of experiments is extremely lengthy and costly. Thus, in order to accelerate the optimization process, an investigation was conducted to develop a method based on the melt pool characterizations. In fact, in these experiments the single tracks of Ti-6Al-4V were deposited by a DED process with multiple laser power, laser speed and focus combinations. Surface morphology and dimensions of single tracks were analyzed and geometrical characteristics of melt pools were evaluated after polishing and etching of cross sections. It was found that the helpful information regarding the selection of optimal process parameters can be achieved from the melt pool features.