Study of the effects of process parameters on deposited single track of M4 powder based direct energy deposition

The Direct energy deposition (DED) process has been a popular method for improving surface properties in mold industries. The deposited bead geometry and dilution depth, representing the thickness of the melted substrate mixed with deposited materials, play an important role in determining the mechanical properties of the deposited part. Therefore, selecting and controlling the DED process parameters is very important for obtaining the optimal deposited bead geometry. This study, investigated the effects of process parameters on deposited single-track geometry using AISI M4 powder. The cross-sectional profile of the deposited bead was analyzed to understand the effects of each processing condition on bead geometry. Moreover, a mathematical formula for bead geometry prediction was derived using the Response surface method (RSM), which can be used to effectively control the process variables to achieve the desired qualities.