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Tardec Direct Energy Deposition Technical Analysis Design of Experiments, Part 1, Phase 1

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TARDEC Production Lifecycle Engineering PLE Group began a Design of Experiments DOE to determine a standard process to optimize parameters settings to validate coatings and repairs conducted with Direct Energy Deposition DED technology. For this DOE, TARDEC used the DM3D 405D laser deposition equipment. The purpose of this DOE is to evaluate the capabilities of this technology to be used in three areas within the US Army surface repairs for cracks and wear, surface repair of corrosion damage, and surface coatings for corrosion prevention. A secondary role of this DOE isto evaluate the current state of the DM3D 405D and to determine what upgrades and modifications would be necessary for this equipment to function in a parameter validation role. Three primary parameters were identified in this DOE as having the most significant effects on the quality of a deposition pattern above all others laser power, powder flow rate,and head feed speed. These parameters have the greatest effects on build height, porosity, fusion, and a wide range of other deposition properties. Since this team conducting the DOE was not provided with any optimal parameter settings or ranges to begin with, this DOE was designed around figuring out how to determine an optimal range for each parameter, and which parameters held the greatest effects over the others for future optimization efforts. Effectively laying the ground work for additional powdered materials to come. This DOE was created with two parts in mind, the first designed to create stable deposition line builds and identifying optimal trends. The second part of the DOE was designed to take the optimal parameter settings developed in the first part, and create standardized specimens to determine material and mechanical properties as they related to the intended function of that specific powder material to be deposited an a specific substrate.

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Technical Report,06 Dec 2016,01 May 2017



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