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

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    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 languageEnglish
    Article number107380
    JournalOptics and Laser Technology
    Early online date14 Jul 2021
    Publication statusPublished - 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


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


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