What is Direct Energy Deposition?
Directed Energy Deposition (DED) is one of the 7 categories of Additive Manufacturing processes. DED forms 3D objects by melting material as it is being deposited using focused thermal energy such as laser, electron beam or plasma arc. Both the energy source and the material feed nozzle are manipulated using a gantry system or robotic arm. DED is increasingly used in hybrid manufacturing where even the substrate bed is moved to create complex shapes.
Although it’s possible to create parts from scratch, due to the nature of how the DED technology works, currently its predominately used for repairing by adding material to an existing part such as turbine blade repair.
DED was developed by Sandia National Laboratories in 1995 under the name of LENS (Laser Engineering Net Shape) and then was commercialized by Optomec Design Company.
Due to the variations in the energy source and final use, DED is sometimes referred to as laser metal deposition (LMD), 3D laser cladding or direct light fabrication.
Types of direct energy deposition
Although DED technology can be used to make metal, ceramic and polymer parts, it is predominately used to make metal parts. DED can be classified into the following groups by the energy source it uses to melt material.
- Laser-based DED systems such as Optomec’s Laser Engineering Net Shape (LENS) DED system uses laser as the main energy source
- Electron beam based DED systems such as Sciaky’s Electron Beam Additive Manufacturing (EBAM) uses an electron beam to melt the powdered material feedstock
- Plasma or Electric arc based DED systems such as Wire arc additive manufacturing (WAAM) DED process uses an electric arc to melt the wire
DED technology can also be subdivided further into the following types based on the types of material feedstock used to create the parts.
- Powder-based DED systems such as Laser Engineered Net shaping (LENS) or Laser metal Deposition (LMD) feed powder through the nozzle and melted by a laser beam or electron beam
- Wire based DED systems feed wires through a nozzle and use laser, plasma arc or electron beam to create the molten pool
How Direct energy deposition works
Different types of DED systems discussed in the previous section work marginally different from each other. However, the core principle can be explained using the above powder-based laser DED system.
Since the process creates a molten metal pool, the DED process typically occurs in a hermetically sealed chamber either, filled with inert gas for laser and arc energy source or vacuum for electron beam systems to stop metal oxidization, especially for reactive materials like Titanium.
The centre of a typical DED system is the nozzle head (figure 2) which consists of the energy source and the powder delivery nozzles which converges at the point of deposit where the laser beam is focused. Nozzle head is mounted on either a multi-axis CNC (Computer Numerical Control) head or an articulated arm. Typically, the build platform is part of the multi-axis CNC system which includes the nozzle head.
- Using the geometric CAD information, both the nozzle head and the build platform is moved to generate the 3D geometrical features
- Laser beam melts the surface and creates a small molten pool of the material on the substrate at the start point along the build path
- The feeders feed the powder through the nozzle into this molten pool
- Using the CAD geometric information, CNC controlled head or the bed or both are moved along the build path to create the metal part feature
Predominantly, DED uses metal in the form of either wire or powder. However, DED technology is also capable of using polymers and ceramics. For example, Arevo makes composite frames using polymer and filament of carbon fibre.
DED supports a wide range of metals as any metal that can be welded can be used to create parts through this technology. Commonly used materials by various manufacturers are as follows;
|Titanium and Titanium alloys||Niobium|
|Inconel 718, 625||Stainless Steels (300 series)|
|Hastelloy||Aluminium alloy 2319, 4043|
Typical direct energy deposition applications
DED is already utilised in key industries like aerospace, defence, oil & gas, as well as the marine industry, for example, aircraft frames and structures, refractory metal components, ballistic material tooling repair and reconditioning and marine propulsion, etc.
Like any other subtractive manufacturing process, parts made using DED can be heat-treated, hot-isostatic-pressed, machined, or finished in any customary manner, which opens various new applications. Most of the hybrid manufacturing systems use DED and have increased in popularity.
Advantages and disadvantages of direct energy deposition
DED technologies are used exclusively in metal additive manufacturing due to the nature of the process and are ideally suited for reDpairing or adding material to existing components.
Advantages of DED
- High build rates – DED’s higher deposition rates at relatively low resolution means faster build rate compared to some other metal additive manufacturing process
- Dense and strong parts – DED creates higher density parts hence their mechanical properties are as good as cast or wrought material
- Near net shape – Parts can be near net shapes requiring minimal amount of post-processing
- Can be used for repairing – Ideally suited for application requiring metal addition to existing parts hence lends itself for repairing applications
- Multi-material range – Latest DED machines have the capability to have several different powders or wire containers which enables to build parts with custom alloy
- Larger parts – Comparably larger parts can be built using DED. For example, Sciaky’s EBAM printers have the capability to print parts a few meters high
- Easy material change – Since the material is fed during the process on demand from separate powder containers, it’s easy to refill or change the material
- Reduced material waste – DED only deposits the material it needs during the process meaning less wastage compared to processes like powder bed fusion (SLS and DMLS) where, the full build platform has to be filled with metal powder
Disadvantages of DED
- High capital cost – Direct energy deposition systems are comparably very expensive to the other types of metal additive manufacturing systems
- Low build resolution – Parts produced using DED technology are lower in resolution with a poor surface finish. It will look like sand or investment castings and would require secondary processing such as machining or aqua blasting, hence adding more time and cost
- No support structures – Due to its nature of how the DED technology builds parts, support structures cannot be used during the build process, hence features like overhangs will not be possible