About this Abstract |
| Meeting |
2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
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| Symposium
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2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
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| Presentation Title |
From Defect to Feature: Controlled Porosity Patterning in Wire-Arc Directed Energy Deposition |
| Author(s) |
Bemnet Molla, Luke Hagedorn, Christopher B. Williams |
| On-Site Speaker (Planned) |
Bemnet Molla |
| Abstract Scope |
Wire-Arc Directed Energy Deposition (DED-Arc) is a low-cost, high-throughput additive manufacturing process capable of fabricating large-scale near-net shape metal parts. While DED-Arc is typically used to produce fully dense or contour-based structures, the ability to spatially tailor density within parts remains largely unexplored. This work presents a novel and generalizable processing technique for manufacturing millimeter-scale porous structures. The method combines waveform modulation with oscillatory toolpaths to control droplet deposition and enable tunable porosity formation. X-ray computed tomography is used to characterize the resulting multi-layer porous structure morphologies, which exhibit equivalent pore diameters of 1–8mm and porosities ranging from 20–60%. The approach is evaluated across two material systems to assess generalizability. ER5556 aluminum establishes process–structure-property relationships, while ER70S-6 mild steel demonstrates transferability across materials and power supply systems. Results show that controlled porous architectures can be produced using standard DED-Arc hardware and process parameter manipulation alone. |
| Proceedings Inclusion? |
Undecided |