In Situ microstructure control during electric-arc-directed energy deposition
Electric-arc-directed energy deposition (Arc-DED) revolutionises 3D metal printing by overcoming powder-based processes’ size and production rate limitations. While powder-based processes are constrained by small build chambers and 3–30 micron layer heights, Arc-DED allows for unlimited build scales...
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| Format: | Article |
| Language: | English |
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Taylor & Francis Group
2025-12-01
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| Series: | Virtual and Physical Prototyping |
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| Online Access: | https://www.tandfonline.com/doi/10.1080/17452759.2025.2499929 |
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| author | Lile Squires Victor K. Champagne Amit Bandyopadhyay |
| author_facet | Lile Squires Victor K. Champagne Amit Bandyopadhyay |
| author_sort | Lile Squires |
| collection | DOAJ |
| description | Electric-arc-directed energy deposition (Arc-DED) revolutionises 3D metal printing by overcoming powder-based processes’ size and production rate limitations. While powder-based processes are constrained by small build chambers and 3–30 micron layer heights, Arc-DED allows for unlimited build scales and 3 mm layer heights, achieving up to 100 times faster deposition rates. Unfortunately, the high energy needed for these rates and thicknesses intensifies the heating and cooling cycles inherent to Arc-DED. This causes significant variations in microstructural and mechanical properties, limiting its use for advanced alloys. This study introduces a conformal top cooling method to regulate the chaotic thermal environment of Arc-DED deposition and produce as-deposited Inconel 718 (IN718) material equivalent to the solutionized condition. The concept is experimentally investigated using cold metal transfer (CMT) of IN718. The role of microstructural and phase uniformity during material production is discussed, material performance in as-deposited and heat-treated conditions is evaluated, processing-property relationships are investigated, and applicability to other materials is addressed. Results show a 45% reduction in process time due to improved thermal management, translating to as-processed microstructural uniformity. Homogeneity in grain growth, controlled phase development, and mechanical testing suggest an as-processed solutionizing effect, with minimised impact of specimen orientation after heat treatment. |
| format | Article |
| id | doaj-art-d02bce0553b849d28e98c2d97fa8d34a |
| institution | Kabale University |
| issn | 1745-2759 1745-2767 |
| language | English |
| publishDate | 2025-12-01 |
| publisher | Taylor & Francis Group |
| record_format | Article |
| series | Virtual and Physical Prototyping |
| spelling | doaj-art-d02bce0553b849d28e98c2d97fa8d34a2025-08-20T03:53:46ZengTaylor & Francis GroupVirtual and Physical Prototyping1745-27591745-27672025-12-0120110.1080/17452759.2025.2499929In Situ microstructure control during electric-arc-directed energy depositionLile Squires0Victor K. Champagne1Amit Bandyopadhyay2W. M. Keck Biomedical Materials Research Lab, School of Mechanical and Materials Engineering, Washington State University Pullman, Pullman, WA, USADEVCOM Army Research Laboratory, Army Research Directorate, Aberdeen Proving Ground, Aberdeen, MD, USAW. M. Keck Biomedical Materials Research Lab, School of Mechanical and Materials Engineering, Washington State University Pullman, Pullman, WA, USAElectric-arc-directed energy deposition (Arc-DED) revolutionises 3D metal printing by overcoming powder-based processes’ size and production rate limitations. While powder-based processes are constrained by small build chambers and 3–30 micron layer heights, Arc-DED allows for unlimited build scales and 3 mm layer heights, achieving up to 100 times faster deposition rates. Unfortunately, the high energy needed for these rates and thicknesses intensifies the heating and cooling cycles inherent to Arc-DED. This causes significant variations in microstructural and mechanical properties, limiting its use for advanced alloys. This study introduces a conformal top cooling method to regulate the chaotic thermal environment of Arc-DED deposition and produce as-deposited Inconel 718 (IN718) material equivalent to the solutionized condition. The concept is experimentally investigated using cold metal transfer (CMT) of IN718. The role of microstructural and phase uniformity during material production is discussed, material performance in as-deposited and heat-treated conditions is evaluated, processing-property relationships are investigated, and applicability to other materials is addressed. Results show a 45% reduction in process time due to improved thermal management, translating to as-processed microstructural uniformity. Homogeneity in grain growth, controlled phase development, and mechanical testing suggest an as-processed solutionizing effect, with minimised impact of specimen orientation after heat treatment.https://www.tandfonline.com/doi/10.1080/17452759.2025.2499929Additive manufacturingwire arc additive manufacturing (WAAM)heat treatmentarc-directed energy deposition (Arc-DED)Inconel 718advanced materials |
| spellingShingle | Lile Squires Victor K. Champagne Amit Bandyopadhyay In Situ microstructure control during electric-arc-directed energy deposition Virtual and Physical Prototyping Additive manufacturing wire arc additive manufacturing (WAAM) heat treatment arc-directed energy deposition (Arc-DED) Inconel 718 advanced materials |
| title | In Situ microstructure control during electric-arc-directed energy deposition |
| title_full | In Situ microstructure control during electric-arc-directed energy deposition |
| title_fullStr | In Situ microstructure control during electric-arc-directed energy deposition |
| title_full_unstemmed | In Situ microstructure control during electric-arc-directed energy deposition |
| title_short | In Situ microstructure control during electric-arc-directed energy deposition |
| title_sort | in situ microstructure control during electric arc directed energy deposition |
| topic | Additive manufacturing wire arc additive manufacturing (WAAM) heat treatment arc-directed energy deposition (Arc-DED) Inconel 718 advanced materials |
| url | https://www.tandfonline.com/doi/10.1080/17452759.2025.2499929 |
| work_keys_str_mv | AT lilesquires insitumicrostructurecontrolduringelectricarcdirectedenergydeposition AT victorkchampagne insitumicrostructurecontrolduringelectricarcdirectedenergydeposition AT amitbandyopadhyay insitumicrostructurecontrolduringelectricarcdirectedenergydeposition |