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Journal of Manufacturing Processes
Article . 2025 . Peer-reviewed
License: CC BY
Data sources: Crossref
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Productive Energy Fluence (PEF) controller using feed and laser hybrid control for Directed Energy Deposition (DED)

Authors: Weijun Zhang; Muqing Yang; Geng Li; Masakazu Soshi;

Productive Energy Fluence (PEF) controller using feed and laser hybrid control for Directed Energy Deposition (DED)

Abstract

In metal additive manufacturing (AM), the laser powder-based directed energy deposition (DED) process stands out as a highly promising approach, enabling rapid, layer-wise fabrication and repair of high-volume, complex geometries. DED supports not only custom-tailored designs with single materials but also enables the use of functionally graded materials. However, the process faces challenges due to the melt pool instability, repeated rapid heating and cooling cycles, uneven heat distribution as layers accumulate, and slower production speed compared to traditional milling processes. These factors complicate the management of geometric accuracy, material properties, residual stress, and overall productivity, thereby limiting broader industrial adoption. A real-time closed-loop energy control system is imperative to improve the general quality of DED parts and to promote a wider application. This study proposes and demonstrates a productive energy fluence (PEF) controller that integrates feed rate and laser power adjustments to enhance geometric accuracy and productivity through optimized temperature management. In this hybrid system, a feed rate (FR)-based energy control strategy was initially activated to maintain the layer's median temperature while enhancing productivity by increasing both the FR and powder flow rate (PFR). This approach leverages the inherent energy accumulation of DED process to enhance productivity by reducing energy fluence (EF) input while maintaining powder fluence (PF) input. Once the FR-based control reached its temperature management limit, the system automatically switched to laser power (LP)-based energy control strategy, dynamically adjusting the EF by regulating LP to stabilize the layer's median temperature and geometric accuracy with minimal LP adjustment. Experiments on step-thin wall geometries and high-aspect-ratio thin walls have demonstrated improved geometric accuracy and reduced production time, achieved by comparing a hybrid control strategy against single LP-based and FR-based energy control strategies, as well as an uncontrolled process.

Country
United States
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Keywords

4017 Mechanical engineering (for-2020), Industrial Engineering & Automation (science-metrix), Additive manufacturing, Closed-loop control, 4014 Manufacturing Engineering (for-2020), Energy control, 0910 Manufacturing Engineering (for), 7 Affordable and Clean Energy (sdg), Directed energy deposition, 40 Engineering (for-2020), 4014 Manufacturing engineering (for-2020), Stainless steel

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selected citations
These citations are derived from selected sources.
This is an alternative to the "Influence" indicator, which also reflects the overall/total impact of an article in the research community at large, based on the underlying citation network (diachronically).
BIP!Citations provided by BIP!
popularity
This indicator reflects the "current" impact/attention (the "hype") of an article in the research community at large, based on the underlying citation network.
BIP!Popularity provided by BIP!
influence
This indicator reflects the overall/total impact of an article in the research community at large, based on the underlying citation network (diachronically).
BIP!Influence provided by BIP!
impulse
This indicator reflects the initial momentum of an article directly after its publication, based on the underlying citation network.
BIP!Impulse provided by BIP!
1
Average
Average
Average
Green
hybrid
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