Process mapping for laser hot wire additive manufacturing of Ti6Al4V

Purpose Laser hot wire additive manufacturing (LHWAM) is a newer technology within the space of large-scale directed energy deposition (DED) additive manufacturing (AM) processes. This study aims to map known AM flaw types such as lack of fusion and keyholing, as well as a dripping flaw unique to hot wire processes, across process parameter space using a small number of single-track experiments. Design/methodology/approach A semianalytical model was calibrated using a small initial set of experimental data. Lack of fusion and keyholing flaws were mapped across process space using existing models. The dripping flaw was modeled via analytical methods calibrated with experimental data, and then mapped across processing space. Further experimental data beyond the small initial set was used to evaluate the accuracy of the process maps developed. A website and executable were deployed to users of the process for convenient rapid process parameter selection. Findings With the process maps generated during this work, users can easily and rapidly generate desirable parameter sets for a range of conditions, enabling the intelligent utilization of the entire stable processing regime. Practical implications The methodology developed can be applied to other LHWAM machines or DED processes to rapidly and inexpensively generate a systematic understanding of processing space for build planning. Originality/value LHWAM shows advantages over other large-scale DED processes, but a systematic physically informed study of the key flaw regions across process space had not been conducted, limiting more widespread use of the process and creating a gap that this study fills.