An Optimization of Manufacturing Process of SS304L Using Direct Energy Deposition Method

Abstract

The direct energy deposition (DED) method is an emerging manufacturing technique that has been recently highlighted due to its capabilities to coat materials with complex geometry for high temperature and highly corrosive environmental applications, such as steam turbine blade. Amongst metallic materials, SS304L has been reported to have superior corrosion resistance in such environments. Therefore, 3D printing of complex-shaped parts using SS304 maybe a promising strategy to introduce 3D printing techniques for nuclear industry application. To obtain robust and stable products that can withstand extreme environments, optimization of the SS304 manufacturing process conditions is required. This study investigated the effects of process parameters including laser power, scan speed, coaxial gas flow, and feeder rate using the DED method with a 4 way nozzle. It was found that laser power has an effect on grain growth behaviors. If the other variables are fixed and the scan speed is above a certain value, then the scan speed does not affect surface oxidation. The feeder rate is related to height. As the feeder rate increases, the height increases. Coaxial gas works to prevent oxidation and damage to the optic components and is not a critical factor in determining the size of the deposited material. These results can be utilized in future studies to accelerate the process design time of other 3D printed materials and future applications using SS304L