Influences of deposition strategies on thermo-mechanical characteristics of a multilayer part deposited by a wire feeding type DED process

Variation in process parameters and deposition strategies has produced different thermo-mechanical characteristics in a part fabricated by a wire feeding type directed energy deposition (DED) process. The purpose of this paper is to select a proper deposition strategy to fabricate a straight wall part using a wire feeding type DED process. The deposition strategies include different deposition directions, deposition patterns and interpass time. In order to investigate the influences of deposition strategies on thermo-mechanical characteristics of fabricated part, three-dimensional finite element analyses (FEAs) have been proposed. A volumetric heat flux has been applied to simulate the transient heat transfer phenomena of the DED process. Influences of different deposition strategies on thermo-mechanical characteristics of fabricated part have been discussed. From the result of residual stress distribution, an appropriate deposition strategy has been selected for the multi-layer deposition. Results of FEAs have been verified through comparison of vertical displacements between estimated results from FEAs and those of experiments.