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Towards directed energy deposition of metals using polymer-based supports: porosity of 316L stainless steel deposited on carb...

Publication Type
Conference Paper
Book Title
2022 International Solid Freeform Fabrication Symposium
Publication Date
Conference Name
Solid Freeform Fabrication Symposium (SFF)
Conference Location
Austin, Texas, United States of America
Conference Sponsor
The Minerals, Metals, and Materials Society
Conference Date

Directed energy deposition (DED) is increasingly valuable to many industries because of its high deposition rates relative to other metal additive manufacturing processes, but the design space of DED is limited. For instance, steep overhangs are difficult or impossible to manufacture. Polymer-based support structures could help address this challenge. The viability of DED on polymer composite substrates has begun to be explored, specifically with 316L stainless steel on carbon-fiber-reinforced ABS substrates. Monolithic metal components can be deposited on the polymer, but it was found that gas release during polymer degradation causes porosity due to gas entrapment in the metal. An interlayer cooling time was introduced to reduce polymer degradation and decrease the porosity due to gas entrapment, but this led to porosity from lack of fusion. The results of this work provide insight into process parameter selection and scan strategy development to enable the use of polymer support structures in blown-powder DED.