It is compelling to realize that the additive manufactured part using wire feeding type directed energy deposition (DED) process is subjected to undesired thermal effects, and induced residual stress during the manufacturing process. In order to improve the quality of the manufactured part, the distributions of temperature and residual stress have to be understood to manage the results of the processing of these materials. The objective of this paper is to investigate the influence of the angle of corner deposition on the distributions of temperature and residual stress of the Ti-6Al-4V deposited bead, and the substrate via thermo-mechanical finite element analyses (FEAs). In the same fashion, the formation of the heat affected zone (HAZ) and the stress influenced region (SIR) are estimated from the measured results of the FEAs. Equally important, it can be stated that from the estimated HAZ and SIR regions, the overlapping of undesired thermal effects and residual stress between two beads fabricated by the wire feeding type DED process can be avoided at the design stage.
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Estimation Method of Interpass Time for the Control of Temperature during a Directed Energy Deposition Process of a Ti–6Al–4V Planar Layer Bih-Lii Chua, Dong-Gyu Ahn Materials.2020; 13(21): 4935. CrossRef
Investigation of Influence of Laser Parameters and Powder Porosity on Thermal Characteristics in the Powder Bed of a SLM Process Kwang-Kyu Lee, Ho-Jin Lee, Hyun-Sik Kim, Dong-Gyu Ahn, Yong Son Journal of the Korean Society for Precision Engineering.2019; 36(8): 761. CrossRef
Wire feeding type directed energy deposition (DED) process is able to produce metal parts with high density at high deposition rate. However, the parts are subjected to high residual stresses and distortion due to its large heat input. In order to simulate the thermal stress, a proper heat input parameter is required. The goal of this paper is to investigate the efficiency and penetration depth of the applied heat flux in the DED process. The estimation method for the penetration depth and efficiency of applied heat flux is proposed using the thermal finite element analyses (FEAs). A finite element model is developed according to the cross sectional profile of the actual deposited beads. A top-hat volumetric heat flux is adopted to simulate the transient thermal phenomenon of the laser based wire feeding type DED process. The estimated heat affected zone (HAZ) from the FEAs is compared with the experimental results in order to estimate the proper efficiency and penetration depth of the laser beam for each condition of DED process.
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Process Kwang-Kyu Lee, Dong-Gyu Ahn, Woo-Sung Kim, Ho-Jin Lee Journal of the Korean Society of Manufacturing Process Engineers.2020; 19(8): 56. CrossRef
Estimation Method of Interpass Time for the Control of Temperature during a Directed Energy Deposition Process of a Ti–6Al–4V Planar Layer Bih-Lii Chua, Dong-Gyu Ahn Materials.2020; 13(21): 4935. CrossRef
A Study on Activation Algorithm of Finite Elements for Three-Dimensional Transient Heat Transfer Analysis of Directed Energy Deposition Process Bih-Lii Chua, Ho-Jin Lee, Dong-Gyu Ahn, Yeqing Wang International Journal of Precision Engineering and Manufacturing.2019; 20(5): 863. CrossRef
Influences of deposition strategies on thermo-mechanical characteristics of a multilayer part deposited by a wire feeding type DED process Bih Lii Chua, Dong-Gyu Ahn, Jae-Gu Kim Journal of Mechanical Science and Technology.2019; 33(12): 5615. CrossRef
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Influence of process parameters on temperature and residual stress distributions of the deposited part by a Ti-6Al-4V wire feeding type direct energy deposition process Bih Lii Chua, Ho Jin Lee, Dong-Gyu Ahn, Jae Gu Kim Journal of Mechanical Science and Technology.2018; 32(11): 5363. CrossRef
Influence of Angle of Corner Deposition on Temperature and Residual Stress Distributions in the Vicinity of the Deposited Region by a Ti-6Al-4V Wire-Feeding Type of Direct Energy Deposition Process Bih Lii Chua, Ho Jin Lee, Dong-Gyu Ahn, Jae Gu Kim Journal of the Korean Society for Precision Engineering.2018; 35(9): 853. CrossRef
Transparent materials are widely used in the fields of optic parts and bio industry. We have experiment to find out the characteristics of the micro machining inside transparent materials using femtosecond laser pulses. With its non-linear effects by very high peak intensity, filament (plasma channel) was formed by the cause of the self-focusing and the self-defocusing. Physical damage could be found when the intensity is high enough to give rise to the thermal stress or evaporation. At the vicinity of the power which makes the visible damage or modification, the structural modification occurs with the slow scanning speed. According to the polarization direction to the scanning direction, the filament quality is quite different. There is a good quality when the polarization direction is parallel to the scanning direction. For fine filament, we could suggest the conditions of the high numerical aperture lens, the short shift of focusing point, the low scanning speed and the low power below 20 ㎽. As the examples of optics parts, we fabricated the fresnel zone plate with the 225 ㎛ diameter and Y-bend optical wave guide with the 5㎛ width.
An experimental study of the femtosecond laser machining of Si materials was carried out. Direct laser machining of the materials for the feature size of a few micron scale has the advantage of low cost and simple process comparing to the semiconductor process, E-beam lithography, ECM and other machining process. Further, the femtosecond laser is the better tool to machine the micro parts due to its characteristics of minimizing the heat affected zone(HAZ). As a result of line cutting of Si, the optimal condition had the region of the effective energy of 2mJ/㎜-2.5mJ/㎜ with the power of 0.5㎽-1.5㎽. The polarization effects of the incident beam existed in the machining qualities, therefore the sample motion should be perpendicular to the projection of the electric vector. We also observed the periodic ripple patterns which come out in condition of the pulse overlap with the threshold energy. Finally, we could machined the groove with the linewidth of below 2 ㎛ for the application of MEMS device repairing, scribing and arbitrary patterning.
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