Direct materials deposition: designed macro and microstructure

Solid freeform fabrication of engineering materials is now possible using the Direct Metal Deposition (DMD) technique. Closed loop optical feedback system for DMD makes realistic components with dimensional accuracy of 0.01 inch. On the other hand, close control of the process parameter can provide microstructure of choice. Such continued capability to control macro and microstructure is creating considerable interest. H13 tool steel is one of the difficult alloys for deposition due to residual stress accumulation from martensitic transformation. However, it is the material of choice for the die and tool industry. DMD offers Copper chill blocks and water cooling channels as the integral part of the tool. On the other hand ZrO(2) was co-deposited with nickel superalloys using DMD. This process thus is amenable to produce both macro and microstructure to a designed specification. This paper briefly reviews the state of the art of DMD and describes the microstructure and mechanical properties of selected engineering alloy systems deposited by DMD.