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Improving laser directed energy deposition with wire feed-stock through beam shaping with a deformable mirror
University West, Department of Engineering Science, Division of industrial automation. (KAMPT)ORCID iD: 0000-0002-8018-6145
University West, Department of Engineering Science, Division of industrial automation. (KAMPT)ORCID iD: 0000-0001-5734-294X
Department of Mechanics, Mathematics and Management, Politecnico di Bari, via Orabona 4, 70125, Bari, (ITA).
Department of Engineering, University of Basilicata, Via Ateneo Lucano 10, 85100, Potenza (ITA).
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2025 (English)In: Optics and lasers in engineering, ISSN 0143-8166, E-ISSN 1873-0302, Vol. 185, article id 108716Article in journal (Refereed) Published
Abstract [en]

This study explores the uncharted territory of beam shaping through a novel deformable mirror system in directed energy deposition laser wire, an emerging area in Additive Manufacturing. While beam shaping has shown substantial benefits in laser processes like welding and powder bed fusion, its potential in this specific domain remains unexploited. The research investigates the influence of three near-elliptical Gaussian beam shapes on melt pool and bead geometries during deposition with stainless-steel wire. The study reveals three distinct processing modes achievable at the same total power through beam shaping, with significant modifications observed in melt pool and bead structures. Reduced bead geometry variation and enhanced process stability were achieved with the beam shape with major axis along the wire feeding direction, and with highest average power density and intermediate peak power density. The findings underscore the potential of beam shaping to enhance robustness and increase energy utilization and productivity in this process.  

Place, publisher, year, edition, pages
Elsevier, 2025. Vol. 185, article id 108716
Keywords [en]
Gaussian beams; Hard facing; Laser beam welding; Laser beams; Laser materials processing; Beam-shaping; DED-LB/w; Deformable mirrors; Directed energy; Directed energy deposition; Energy depositions; Feed stock; Feed-stock wire; Heat input control; Melt pool; Melt pool geometry; Laser mirrors
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology
Identifiers
URN: urn:nbn:se:hv:diva-22716DOI: 10.1016/j.optlaseng.2024.108716ISI: 001371741700001Scopus ID: 2-s2.0-85210129114OAI: oai:DiVA.org:hv-22716DiVA, id: diva2:1923088
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CC BY 4.0

Available from: 2024-12-20 Created: 2024-12-20 Last updated: 2024-12-20

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Mi, YongcuiSikström, FredrikAncona, Antonio

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