Probing dimensional consistency of deposited structures during out-of-position wire arc directed energy deposition

  • Wire arc directed energy deposition (DED-Arc) using a gas metal arc (GMA) welding power source is cited as DED-GMA that fabricates a part by layer-by-layer deposition of molten wire droplets along horizontal and out-of-position inclined trajectories. For the out-of-position trajectories, a smooth deposition of material is impaired by the gravitational force on the molten wire droplets, resulting in uneven and inconsistent deposit profiles. We present here a detailed experimental investigation to realize the effect of the out-of-position inclinations on the quality of the deposited structure for DED-GMA with a steel and an aluminium filler wire. The evolution of the droplet transfer and melt pool during the out-of-position inclined deposition is probed through high-speed videography at different baseplate angles and commonly used scanning strategies. An analytical model is proposed further based on force equilibrium analysis for a prior estimation of the out-of-position inclined depositWire arc directed energy deposition (DED-Arc) using a gas metal arc (GMA) welding power source is cited as DED-GMA that fabricates a part by layer-by-layer deposition of molten wire droplets along horizontal and out-of-position inclined trajectories. For the out-of-position trajectories, a smooth deposition of material is impaired by the gravitational force on the molten wire droplets, resulting in uneven and inconsistent deposit profiles. We present here a detailed experimental investigation to realize the effect of the out-of-position inclinations on the quality of the deposited structure for DED-GMA with a steel and an aluminium filler wire. The evolution of the droplet transfer and melt pool during the out-of-position inclined deposition is probed through high-speed videography at different baseplate angles and commonly used scanning strategies. An analytical model is proposed further based on force equilibrium analysis for a prior estimation of the out-of-position inclined deposit profile, which can help design dimensionally consistent and structurally sound parts using DED-GMA.zeige mehrzeige weniger

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Autor*innen:Gaurav Dak, Birendra Kumar Barik, Prashant Kumar ChaurasiaORCiD, Götz-Friedrich Gottschalk, Akshay Manoj Shahane, Sven-F. Goecke, Amitava DeORCiD
Dokumenttyp:Zeitschriftenartikel
Veröffentlichungsform:Verlagsliteratur
Sprache:Englisch
Titel des übergeordneten Werkes (Englisch):Welding in the World
Jahr der Erstveröffentlichung:2025
Organisationseinheit der BAM:9 Komponentensicherheit
9 Komponentensicherheit / 9.3 Schweißtechnische Fertigungsverfahren
Verlag:Springer Science and Business Media LLC
Erste Seite:1
Letzte Seite:20
DDC-Klassifikation:Technik, Medizin, angewandte Wissenschaften / Ingenieurwissenschaften / Ingenieurwissenschaften und zugeordnete Tätigkeiten
Freie Schlagwörter:Additive manufacturing; DED-Arc; Force; High-speed videography; Out-of-position deposition
Themenfelder/Aktivitätsfelder der BAM:Material
Material / Additive Fertigung
DOI:10.1007/s40194-025-02291-0
ISSN:0043-2288
Verfügbarkeit des Dokuments:Datei im Netzwerk der BAM verfügbar ("Closed Access")
Datum der Freischaltung:14.01.2026
Referierte Publikation:Ja
Datum der Eintragung als referierte Publikation:14.01.2026
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