Structured surface feature classification on DED-printed parts. Exemplary data and comprehensive influences listing

Area of Science:

• Additive Manufacturing
• Materials Science
• Surface Engineering

Background:

• Directed Energy Deposition (DED) is an additive manufacturing technology used for producing medium to large metal structures economically.
• The DED process inherently creates a layered surface structure from molten material.
• This characteristic surface topology negatively impacts the mechanical strength of DED-processed workpieces under static and cyclic loads.

Purpose of the Study:

• To highlight the critical importance of surface topology evaluation in assessing the quality and performance of Directed Energy Deposition components.
• To provide a structured approach for assessing surface features in real-world DED workpieces.
• To bridge the gap between technical specifications and visual representation of surface features.

Main Methods:

• Collection of comprehensive examples of structured feature assessments from actual Directed Energy Deposition manufactured parts.
• Detailed documentation of surface topology characteristics.
• Correlation of visual topology appearances with tabular technical specifications of surface features.

Main Results:

• Demonstrated the link between specific surface features and potential mechanical weaknesses in DED parts.
• Provided a visual library of surface topology variations encountered in DED components.
• Established a methodology for supplementing quantitative surface data with qualitative visual analysis.

Conclusions:

• Surface topology assessment is indispensable for ensuring the structural integrity and reliability of Directed Energy Deposition parts.
• The presented examples and methodology aid in a more thorough evaluation of DED workpieces.
• Integrating visual and tabular data enhances the understanding and assessment of DED surface quality.