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About this Abstract
Meeting 2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
Symposium 2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
Presentation Title Process Parameter Optimization for Overlapped Regions in Hybrid LP-DED
Author(s) James David Wateska, Carolyn Seepersad
On-Site Speaker (Planned) James David Wateska
Abstract Scope Overlapped regions in hybrid additive manufacturing are challenging to produce with high volumetric accuracy and metallurgical continuity. Corners overbuild where the toolpath doubles onto itself, while lateral beads require careful overlap selection to ensure fusion between adjacent tracks. This study investigates process parameter optimization to enhance volumetric consistency and metallurgical continuity in powder-blown Directed Energy Deposition of 17-4 PH stainless steel. For corners, a space-filling design of experiments samples additive parameters across varying corner angles and layer counts. Volumetric data near the corner peak is used to guide parameter selection for reducing overbuild. For lateral beads, metallurgical continuity between adjacent beads is assessed using dilution and wetting angle. A semi-analytical relationship captures powder catchment efficiency and informs a thermal finite element model for predicting bead overlap behavior. The proposed strategies are validated experimentally for corners and through simulation for lateral beads, demonstrating improved volumetric fidelity and predicted metallurgical continuity.
Proceedings Inclusion? Undecided

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