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

doi:10.1016/j.optlastec.2021.107380

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

Malayer University

Research output: Contribution to journal › Article › peer-review

68 Citations (Scopus)

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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 language	English
Article number	107380
Journal	Optics and Laser Technology
Volume	144
Early online date	14 Jul 2021
DOIs	https://doi.org/10.1016/j.optlastec.2021.107380
Publication status	Published - Dec 2021

Bibliographical note

NOTICE: this is the author’s version of a work that was accepted for publication in Optics and Laser Technology. Changes resulting from the publishing process, such as peer review, editing, corrections, structural formatting, and other quality control mechanisms may not be reflected in this document. Changes may have been made to this work since it was submitted for publication. A definitive version was subsequently published in Optics and Laser Technology, 144, (2017)
DOI: 10.1016/j.optlastec.2021.107380

© 2021, Elsevier. Licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International http://creativecommons.org/licenses/by-nc-nd/4.0/

Keywords

additive manufacturing
Direct laser metal deposition
Inconel 718
Design of experiments
Optimization

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10.1016/j.optlastec.2021.107380

Post-PrintAccepted author manuscript, 1.78 MBLicence: CC BY-NC-ND

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title = "Direct laser metal deposition additive manufacturing of Inconel 718 superalloy: Statistical modelling and optimization by design of experiments",

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.",

keywords = "additive manufacturing, Direct laser metal deposition, Inconel 718, Design of experiments, Optimization",

author = "Mahmoud Moradi and Arman Hasani and Zeynab Pourmand and Jonathan Lawrence",

note = "NOTICE: this is the author{\textquoteright}s version of a work that was accepted for publication in Optics and Laser Technology. Changes resulting from the publishing process, such as peer review, editing, corrections, structural formatting, and other quality control mechanisms may not be reflected in this document. Changes may have been made to this work since it was submitted for publication. A definitive version was subsequently published in Optics and Laser Technology, 144, (2017) DOI: 10.1016/j.optlastec.2021.107380 {\textcopyright} 2021, Elsevier. Licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International http://creativecommons.org/licenses/by-nc-nd/4.0/ ",

year = "2021",

month = dec,

doi = "10.1016/j.optlastec.2021.107380",

language = "English",

volume = "144",

journal = "Optics and Laser Technology",

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T1 - Direct laser metal deposition additive manufacturing of Inconel 718 superalloy

T2 - Statistical modelling and optimization by design of experiments

AU - Moradi, Mahmoud

AU - Hasani, Arman

AU - Pourmand, Zeynab

AU - Lawrence, Jonathan

N1 - NOTICE: this is the author’s version of a work that was accepted for publication in Optics and Laser Technology. Changes resulting from the publishing process, such as peer review, editing, corrections, structural formatting, and other quality control mechanisms may not be reflected in this document. Changes may have been made to this work since it was submitted for publication. A definitive version was subsequently published in Optics and Laser Technology, 144, (2017) DOI: 10.1016/j.optlastec.2021.107380 © 2021, Elsevier. Licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International http://creativecommons.org/licenses/by-nc-nd/4.0/

PY - 2021/12

Y1 - 2021/12

N2 - 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.

AB - 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.

KW - additive manufacturing

KW - Direct laser metal deposition

KW - Inconel 718

KW - Design of experiments

KW - Optimization

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VL - 144

JO - Optics and Laser Technology

JF - Optics and Laser Technology

M1 - 107380

ER -

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

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