Accelerated Process Parameter Optimization for Directed Energy Deposition of 316L Stainless Steel

Among additive manufacturing technologies, Directed Energy Deposition (DED) processes enable the part production by melting and depositing material where needed according to a CAD design. In DED processes, a laser is focused into a narrow spot to heat a substrate, melt a portion of that and simultaneously melt powder that is being deposited into the melt pool. Traditionally, the process parameters optimization has been done by simple shape specimens fabrication followed by metallography observations. However, this process is time-consuming and expensive. In this study, a quick approach is developed to optimize the process parameters in a short period of time without wasting material. Moreover, it is shown that in the fabrication of 316L stainless steel components by DED process, apart from the process parameters, other factors such as the type of powder, powder preheating and carrier gas flow rate play important roles in the final oxide content.