Directed energy deposition-arc (DED-Arc) and numerical welding simulation as a method to determine the homogeneity

This research presents a hybrid approach to for the prediction of the homogeneity of mechanical properties in 3D metal parts manufactured using directed energy deposition-arc (DED-Arc). DED-Arc is an additive manufacturing process which can offer a cost-effective way to manufacture 3D metal parts, due to high deposition rate of up to 8 kg/h. Regression equations developed in a previous study were used to predict the mechanical properties of a wall structure using only the cooling time t8/5 calculated in a numerical welding simulation. The new approach in this research paper contains the prediction of the homogeneity of the mechanical properties, especially hardness, in 3D metal parts, which can vary due to localized changes in t8/5 cooling time provoked by specific geometrical features or general changes in dimensions. In this study a method for the calculation of the hardness distribution on additively manufactured parts was developed and shown.