A Novel Additive Manufacturing Process Based on Joule Direct Energy Deposition with Laser Assistance: Continuous Directional Deformation Deposition

Abstract This paper introduces a novel framework for high-speed metal wire additive manufacturing using Joule direct energy deposition and a secondary assisted heat source, such as a laser or electric arc. This forming process is defined as wire and Joule additive manufacturing (WJAM) or Continuous Directional Deformation Deposition (CDDD). The WJAM process separates the melting of the feedstock from the generating of the molten pool, that is to say, the melting of feedstock and the generating of molten pool are two independent controllable processes, thereby enhancing control over metal deformation and allowing the use of various metals. The experiments mainly included multiple materials (Ti-6Al-4V and Inconel 718, etc.) parts were printed based on the additive manufacturing machine prototype assembled by the author team of this article, and simulation via the finite element method (FEM) which demonstrated the thermal characteristics and the minimal laser power requirements. The WJAM process is efficient, cost-effective, high upper limit of deposition rate, and capable of producing complex and large parts with superior mechanical properties without the necessity for subsequent heat treatment. This paper elucidates the advantages of the WJAM over analogous technologies and its capacity to transform metal additive manufacturing.