Advanced Fabrication of Shaped Consumable Inserts Using Directed Energy Deposition Additive Manufacturing

A novel, efficient, and adaptable method for manufacturing shaped consumable inserts used in welding is now possible utilizing directed energy deposition (DED) additive manufacturing (AM). Conventional fabrication approaches, such as rolling, machining, and laser-based techniques pose multiple challenges including high material waste, material and geometric limitations, long production times, and elevated costs. In contrast, the proposed DED-based technique allows for near-net-shape production of complex geometries with minimal post-processing and reduced cost, offering a compelling alternative for high-performance industries and a reduction in workforce skill.

Authors: Michael Carney, Travis Peterson (EWI)