Joining of elements fabricated by a robotized laser/wire directed energy deposition process by using an autogenous laser welding

A robotized laser/wire directed energy deposition (RLW-DED) process has been employed, specifically in applications where higher deposition rates or larger buildup envelopes are needed. However, this process might have limitations in printing certain complex shape parts. Fabricating parts with overhang sections, depending on the geometry, might cause a collision between the laser head and the buildup. Part segmentation and joining the elements back together has been presented to overcome those limitations. In this study, the welding of additively manufactured parts by RLW-DED has been proposed. Autogenous laser welding, performed at the same setup used for RLW-DED, was utilized to join the thin-walled 316LSi DED parts. Mechanical and microstructural testing were then performed on the welded samples. The results showed that the mechanical properties of welded DED parts are comparable with those of DED parts. Furthermore, a component of complex shape was fabricated to show the capability of the developed process. Therefore, the welding of RLW-DED parts can expand the application of 3D-printed parts in industry.