Improving laser directed energy deposition with wire feed-stock through beam shaping with a deformable mirror

This study explores the uncharted territory of beam shaping through a novel deformable mirror system in directed energy deposition laser wire, an emerging area in Additive Manufacturing. While beam shaping has shown substantial benefits in laser processes like welding and powder bed fusion, its potential in this specific domain remains unexploited. The research investigates the influence of three near-elliptical Gaussian beam shapes on melt pool and bead geometries during deposition with stainless-steel wire. The study reveals three distinct processing modes achievable at the same total power through beam shaping, with significant modifications observed in melt pool and bead structures. Reduced bead geometry variation and enhanced process stability were achieved with the beam shape with major axis along the wire feeding direction, and with highest average power density and intermediate peak power density. The findings underscore the potential of beam shaping to enhance robustness and increase energy utilization and productivity in this process. • Beam shaping for laser directed energy deposition with feed-stock wire was studied. • A deformable mirror-based adaptive beam shaping system was utilized. • In-situ and post-process data were qualitatively and quantitatively evaluated. • Surface variation decreased by aligning elliptical beam with wire feed. • Effectiveness in energy utilization and productivity was revealed.