Principal investigator: Bryan Webler
University: Carnegie Mellon University
Industry partner: Ametek Specialty Metal Products
Powder-feed direct energy deposition (PF-DED) is an additive manufacturing (AM) technology that enables the rapid production of large parts. Typical feedstock materials are inert gas atomized (GA) metal powder, but water atomized (WA) powders have proven to be a lower-cost alternative. However, WA powders have irregular shapes and high oxygen contents. The proposed work will investigate the effect of these attributes on PF-DED build outcomes. Builds of single-tracks, cubes, and complex structures will be completed. Part geometry and microstructure characterization results will be compared to other AM methods (laser powder bed fusion, LPBF) and builds made from GA powders. The steps needed to design PF-DED processes using WA powder will be identified. The results will support further use of WA powder in AM applications as a potential cost saving alternative.