Laser Deposition of Metals for Shape Deposition Manufacturing

Abstract

A laser/powder deposition process has been added to the Shape Deposition Manufacturing system
\nat Stanford University. This process is more robust than previous SDM metal deposition
\nprocesses, consistently producing fully dense, near-net shape deposits with excellent material
\nproperties Material is deposited by scanning the laser across a surface while injecting metallic
\npowders into the melt-pool at the laser focus. A number of parts have been produced with the
\nsystem, including an injection molding tool, multimaterial structures and simple mechanisms.
\nCurrently research is being perfonned to improve the finish quality of the parts. One of the main
\nareas of research involves controlling thermal stresses which can lead to warpage and
\ndelamination. Selective deposition techniques and the use of low coefficient of thennal expansion
\nmaterials such as INVARTM show promise for reducing defonnations caused by internal stresses.