Planning the process parameters during Direct Metal Deposition of functionally graded thin-walled parts based on a 2D model

The need for functionally graded material (FGM) parts has surfaced with the development of material science and additive manufacturing techniques. Direct Metal Deposition (DMD) processes can locally deposit different metallic powders to produce FGM parts. Yet inappropriate mixing of materials without considering the influence of varying dilution rates and the variation of material properties can result in inaccurate material composition ratios when compared to the desired or computed compositions. Within such a context, this paper proposes a 2D simulation based design method for planning the process parameters in the DMD manufacturing of designed thin-walled parts. The proposed scheme is illustrated through two case studies, one of which is a part with one-dimensional varying composition and the other with two dimensional variation. Using the proposed method, the process parameters can be planned prior to the manufacturing process, and the material distribution deviation from the desired one can be reduced.