Magnetic manipulation in directed energy deposition using a programmable solenoid

Laser directed energy deposition is useful for the manufacture and repair of aerospace components. Its inability to focus powder streams into narrow concentrations limits application for production of fine (<1 mm) features. In the case of magnetic feedstock materials, use of a magnetic field in the track vicinity can allow successful manipulation of track properties. In this work, a solenoid coaxially aligned to the laser beam is used to manipulate track dimensions and powder behaviour. A methodology is demonstrated which allows magnetic fields to dynamically manipulate processing conditions. An improvement to material efficiency of 25 % was achieved, and the effects of critical parameters were also examined. A solenoid fixed to a specific location along the toolpath was used to increase the cross-sectional area of tracks by up to 83 % in those positions. The placement of magnetic fields in the deposition zone were systematically investigated to better understand the mechanisms of powder incorporation. Magnetic manipulation of magnetic feedstocks in DED should therefore be considered as an adaptive control technique in cases where greater control of track dimensions or enhanced material feed control is required.

Automated summary

Laser directed energy deposition is useful for aerospace component manufacture and repair, but its application for fine features is limited. This study demonstrated the use of a solenoid to manipulate track dimensions and powder behavior, leading to a 25% material efficiency improvement and examination of critical parameters.